Mechanical dicers and their use

Abstract

The present inventions relate to methods, systems, apparatuses, controllers, software, and composition of matter associated with rotary dicing of target starting material to generate components. The components may be utilized for energy manipulation device, e.g., battery. The components may be of a battery cell, e.g., a stacked arrangement of battery cells.

Description

MECHANICAL DICERS AND THEIR USEPRIORITY APPLICATIONS

[0001] This application claims priority to U.S. Provisional Patent Application Serial No. 63 / 566,656, filed March 18, 2024, which is incorporated herein by reference in its entirety.BACKGROUND

[0002] The present invention relates to generation of components for energy manipulation devices, e.g., batteries. The energy manipulation devices may undergo charging and discharging of electricity. In some embodiments, such generation of components is adaptable, precise, and / or low-cost. This disclosure includes applicable, devices, methods, systems, apparatuses (e.g., control systems), and software, for generating the components such as by mechanical dicing. The generation of the components may include fabrication and / or manufacturing.

[0003] The present invention relates to methods and structures such as electrode assemblies for use in energy manipulation (e.g., storage) devices such as secondary batteries, to energy manipulation (e.g., storage) devices employing such structures, to methods for manufacturing such structures and / or energy manipulation devices, and applicable systems, apparatuses (e.g., control systems), and software.

[0004] The present invention relates to methods and structures such as electrode assemblies for use in energy manipulation (e.g., storage and / or release) devices such as batteries, to energy manipulation devices employing such structures, and to methods for manufacturing such structures and energy manipulation devices, and applicable systems, apparatuses (e.g., control systems), and software.

[0005] Batteries are a type of energy manipulation device having electrochemical cells in which carrier ions travel between a cathode structure and an anode structure through an electrolyte within each electrochemical cell (e.g., voltaic cell) abbreviated herein as “cell.” The anode structure and cathode structure in the cell are separated by a gap. The cell may include a separator structure. The separator structure may be incorporated in the battery cell during assembly of the battery and during battery operation. Anode and cathode current collectors of the respective anode and cathode, pool electric current from the respective active electrochemical electrodes and enable transfer (e.g., flow) of the current to the environment outside the battery.

[0006] There are a number of shortcomings related to fabrication (e.g., manufacturing) such energy manipulation devices and / or the process of making these energy manipulation devices. Efficiently cutting of energy manipulation (e.g., battery) cell parts may require design changes, e.g., based at least in part on requested placement of the energymanipulation device as part of the electronic product which it serves, e.g., the target product. Some cutting tools (a) use a relatively slow operation, (b) are slow to accommodate design changes, (c) are expensive to accommodate design changes, and / or (d) introduce (e.g., cause) deformations in the cell parts during cutting of the requested components to the requested dimension. Accommodating design changes may include changes in materialization of the design changes to produce the cut part, e.g., adjusting the cutting tool to cut according to the altered design. The components may comprise cell components. The introduced deformation may comprise introduced deterioration in the cut component. The introduced deformation may include introduced deformation of portions of electrodes such as deformation of (e.g., within) an active material operatively coupled with a current collector. The operative coupling may include contacting and / or electrically coupling.

[0007] Lithium-based secondary batteries are a type of energy storage device having cells in which carrier ions, such as lithium, sodium, potassium, calcium or magnesium ions, travel between a cathode structure and an anode structure through an electrolyte within each cell. The anode structure and cathode structure are separated by a separator structure during assembly of the battery and during battery operation. Anode and cathode current collectors pool electric current from the respective active electrochemical electrodes and enable transfer of the current to the environment outside the battery.

[0008] There are a number of shortcomings related to secondary batteries and the process of making secondary batteries. For example, secondary battery electrodes are often manufactured using a laser dicing technique. However, laser dicing can cause redeposition of electrode materials onto the surface of the electrodes as a result of vaporization and debris. Additionally, some of the electrode material may be degraded during the laser dicing process - resulting in non-functional active materials. Other techniques used in the industry include mechanical dicing using linear dies and / or stamps. However, these techniques require stop and go processing, and would not allow for continuous processing of electrodes in a roll-to-roll format. Accordingly, systems and methods are disclosed herein for employing rotary die cutting technologies for mechanical dicing of secondary battery electrodes in order to replace laser dicing of secondary battery electrodes. The systems and methods disclosed herein allow for faster, more precise, and cleaner dicing while allow for roll-to-roll continuous processing of secondary battery electrodes.SUMMARY

[0009] In some aspects, the present disclosure resolves one or more of the aforementioned hardships and / or shortcomings. In some embodiments, the present disclosure provides solutions to curtail the aforementioned hardships and / or shortcomings. The solutions include method(s), device(s), apparatus(es), system(s), and / or design(s). In some aspects, the present inventions relate to method(s), device(s), apparatus(es), system(s), and design(s), utilized for a battery comprising cell(s). Methods, apparatuses, devices, program instructions, and structures, are disclosed herein to cut requested designs that can be quickly and / or cheaply be adjusted to different designs. Cutting the requested design using these dynamically adjustable cutting tools, may be configured to minimize introduction of defects to the resulting cut components.

[0010] In some aspects, disclosed herein is a dynamically adjustable cutting tools - such as rotary dicers - and applicable methods, systems, apparatuses (e.g., control systems), and software. The adjustable cutting tools can include a relief structure configured to cut, or dice, a target to a requested design as the relief structure is pressed onto the target, thus forming a die of the requested design, the relief structure being an elevated element relative to a plane (e.g., sheet or foil), the design is raised above a planar (e.g., flat) background of the relief structure. The target may be in the form of an elongated foil, or sheet. The relief structure can include a sharp design of a hard material (e.g., solid material) used to cut and / or press upon a target starting material. The target starting material may be (e.g., continuously) fed into the adjustable cutting tool to sequentially generate the requested components according to a relief design. The adjustable cutting tools may be configured to progressively cut the design along one or more circumference sides of the design. A relief design may be a sheet operatively coupled with a roller of the adjustable cutting tool. A relief design may be relatively quickly generated. A relief structure (e.g., sheet) may be readily replaceable in the adjustable cutting tool. The adjustable cutting tools may be controllable, e.g., using any of the control systems disclosed herein such as using a control software.

[0011] In another aspect, a method for manufacturing electrodes of a secondary battery using a rotary die assembly, the method comprises: producing, using a first die of the rotary die assembly, a cathode component of an electrode assembly of the secondary battery; producing, using a second die of the rotary die assembly, an anode component of the electrode assembly of the secondary battery; and producing, using a third die of the rotary die assembly, a separator component of the electrode assembly of the secondary battery.

[0012] In another aspect, a rotary die assembly for manufacturing electrodes of a secondary battery, the rotary die assembly comprising a first die, a second die, and a third die, wherein the rotary die assembly is configured to: produce, using the first die of the rotary die assembly, a cathode component of an electrode assembly of the secondary battery;produce, using the second die of the rotary die assembly, an anode component of the electrode assembly of the secondary battery; and produce, using the third die of the rotary die assembly, a separator component of the electrode assembly of the secondary battery.

[0013] In another aspect, a device for processing a target starting material, the device comprising: a frame; an internal roller having a first lateral axis, the internal roller being operatively coupled with the frame, the internal roller being configured to operatively couple with a die to generate a die roller, the internal roller being configured to couple with the die such that upon rotation (e.g., revolution) of the internal roller the die remains (e.g., substantially) stationary relative to the internal roller; and a supportive roller having a second lateral axis (e.g., substantially) parallel to the first lateral axis, the supportive roller being separated from the internal roller by a gap, the supportive roller and the internal roller being configured to rotate relative to each other, such that during their rotation (i) the target starting material is pulled into the gap, (ii) the target starting material interacts with die, interaction of the die with the target starting material resulting in a pattern of the die being compressed onto the target starting material to cut, indent, or cut and indent, the target starting material to generate a product according to the pattern of the die, or (iii) any combination of (i) and (ii). In some embodiments, (a) the device being configured to process the target starting material that comprises a planar material operatively coupled with a particulate material mass, the planar material comprising a foil or a sheet, without (e.g., substantially) deforming the particulate material mass; (b) the device being configured to dynamically alter the gap; (c) the device being configured to dynamically alter compression of the die onto the target starting material; (d) the die being optimized to reduce variance in a force required to compress the die onto the target starting material, the variance being dependent at least in part on a design layout of the die; (e) the internal roller is configured to operatively couple with a die at least in part by using an attractive force; (f) the device being configured to operate in an enclosure having an internal environment different from an ambient environment external to the enclosure, the product being susceptible to one or more reactive agents present in the ambient environment; (g) at least one component of the device is configured for temperature conditioning; (h) die comprising at least one coating configured to lessen an occurrence of portions of the target starting material adhering to the die after processing of the target starting material; (i) the die and the target starting material including at least one type of material in common; or (j) any combination thereof. In some embodiments, the device is configured to process the target starting material that comprises a planar material operatively coupled with the particulate material mass. In some embodiments, the particulate material mass is an anode active material, and the planar material is a current collector with which the anode active material is coupled. In some embodiments, the anode active material comprises a protective material configured to becleaned from the product. In some embodiments, the protective material comprising a binder or a coating. In some embodiments, the device is configured to process the particulate material mass without (e.g., substantially) deforming the particulate material mass. In some embodiments, deforming the particulate material mass comprises introducing one or more defects comprising cracks, dislocations, unwanted growth centers, any types thereof, or any combination thereof. In some embodiments, the unwanted growth centers comprise (a) crystallization centers, (b) metallurgical phases, (c) grown centers accumulation of a reduced phase of charge carriers, or (d) any plurality of types thereof, or (e) any combination thereof. In some embodiments, device is configured to dynamically alter the gap. In some embodiments, dynamic alteration of the gap is dependent at least in part on the target starting material, a relative revolution of the die roller relative to the supporting roller, a design of the die, a fidelity requested from the product, or any combination thereof. In some embodiments, (I) the higher the fidelity the lower the revolution speed, (II) the greater a fragility of the material, the lower the revolution speed. In some embodiments, alteration of the gap is done at least in part using a control system. In some embodiments, alternation of the gap is done using (a) a feedback control scheme, (b) feed forward control scheme, (c) a lookup table, (d) historical measurements, or (e) any combination thereof. In some embodiments, the device being configured to dynamically alter compression of the die onto the target starting material. In some embodiments, dynamic alteration of the compression is dependent at least in part on the target starting material, a relative revolution of the die roller relative to the supporting roller, a design of the die, a fidelity requested from the product, or any combination thereof. In some embodiments, (I) the higher the fidelity the lower the revolution speed, (II) the greater a fragility of the material, the lower the revolution speed. In some embodiments, alteration of the gap is done at least in part using a control system. In some embodiments, alternation of the gap is done using (a) a feedback control scheme, (b) feed forward control scheme, (c) a lookup table, (d) historical measurements, or (e) any combination thereof. In some embodiments, the die is optimized to reduce variance in a force required to compress the die onto the target starting material during the interaction, the variance being dependent at least in part on a design (e.g., design layout) of at least one relief of the die. In some embodiments, the design of the at least one relief is minimized such that (A) minimal extent of the target starting material is cut at each interaction with of the die with the target starting material upon operation of the device and / or (B) a similar extent of the target starting material is cut at each interaction with of the die with the target starting material upon operation of the device In some embodiments, the internal roller is configured to operatively couple with a die at least in part by using the attractive force. In some embodiments, the attractive force comprises a magnetic force, mechanical force, hydraulic force, gas force, or any combination thereof. In some embodiments, the gas force comprisesa pneumatic force or vacuum. In some embodiments, the attractive force comprises a magnetic force. In some embodiments, the device is configured to operate in an enclosure having an internal environment different from an ambient environment external to the enclosure, the product being susceptible to one or more reactive agents present in the ambient environment. In some embodiments, the enclosure comprises a clean room. In some embodiments, the enclosure is configured to separate the internal environment of the enclosure from the ambient environment external to the enclosure. In some embodiments, the separation comprises sealing. In some embodiments, the sealing can be hermitic sealing. In some embodiments, the sealing comprises particulate material (e.g., dust) sealing, liquid sealing, gas sealing, or any combination thereof. In some embodiments, the one or more reactive agents comprise oxygen, water, alcohol, thiol, sulfuric acid, phosphoric acid, carboxylic acid, hydrogen sulfide, any plurality thereof, or any combination thereof. In some embodiments, the internal environment comprises argon, nitrogen, clean dry air, or any combination thereof. In some embodiments, the internal environment has a temperature, pressure, and / or one or more reactive agents, different than those in the ambient environment. In some embodiments, the at least one component of the device is configured for temperature conditioning. In some embodiments, the at least one component comprises the internal roller, the supporting roller, the frame, or any combination thereof. In some embodiments, the temperature conditioning is controlled. In some embodiments, the temperature conditioning comprises heating. In some embodiments, the temperature conditioning comprises cooling. In some embodiments, the at least one component is operatively coupled to, or includes, one or more channels configured to alter a temperature of the at least one component. In some embodiments, one or more channels are configured for flow of a fluid. In some embodiments, the fluid comprises a gas, a liquid, a semisolid, or any combination thereof; wherein the one or more components comprise a rod configured for heat transfer. In some embodiments, the rod comprises an elemental metal or a metal alloy. In some embodiments, the rod comprises silver, copper, aluminum, graphene, gold, aluminum nitride, or boron arsenide. In some embodiments, alteration of the temperature of the at least one component is during use of the device to generate the product. In some embodiments, alteration of the temperature of the at least one component is controlled at least in part by a control system. In some embodiments, the temperature conditioning is active. In some embodiments, the temperature conditioning is. In some embodiments, the temperature conditioning comprises heating. In some embodiments, the temperature conditioning comprises cooling. In some embodiments, the temperature conditioning facilitates increasing accuracy, fidelity, and / or integrity, of the product. In some embodiments, the temperature conditioning facilitates reduces deformation with respect to the target starting material. In some embodiments, the deformation is of a particulatematerial mass as part of the target starting material. In some embodiments, the deformation comprises introducing one or more defects comprising cracks, dislocations, unwanted growth centers, any types thereof, or any combination thereof. In some embodiments, the unwanted growth centers comprise (a) crystallization centers, (b) metallurgical phases, (c) grown centers accumulation of a reduced phase of charge carriers, or (d) any plurality of types thereof, or (e) any combination thereof. In some embodiments, the die comprises at least one coating configured to lessen the occurrence of portions of the target starting material adhering to the die after processing of the target starting material. In some embodiments, the coating comprises polytetrafluoroethylene, polyfluoroalkyl, perfluoroalkyl substances, non-stick ceramic coating, carbon steel, stainless steel, silicone, Gore-Tex, siloxane, silane, oxidized regenerated cellulose, any plurality of types thereof, or any combination thereof. In some embodiments, the device is configured for integration with one or more other processes and / or mechanisms to fabricate a requested product from the product, a system comprising the product, or a system comprising the requested product. In some embodiments, the other processes comprise deposition, compression, calendering, roll-to-roll, cutting, forming, machining, welding, punching, casing, depositing, drying, spraying, 3D printing, calendering, compressing, ablating, dicing, adhering (e.g., gluing), soldering, any plurality of types thereof, or any combination thereof. In some embodiments, to fabricate a requested product from the product comprises to manufacture. In some embodiments, the device is configured to provide the product at least in part using an attractive force and / or a repulsive force. In some embodiments, the attractive force comprises a magnetic force, mechanical force, hydraulic force, gas force, an electrostatic force, or any combination thereof. In some embodiments, the gas force comprises a pneumatic force or vacuum. In some embodiments, an element of the mechanical force may comprise a wiper, a shovel, a loader, a fork, a grappler, a mover, a broom, any plurality of types thereof or any combination thereof. In some embodiments, the mechanical force is part of a robotic system. In some embodiments, the attractive force comprises a gravitational force of the ambient environment. In some embodiments, the die and the target starting material include at least one type of material in common. In some embodiments, the target starting material comprises a current collector, and the at least one type of material is the material type of the current collector. In some embodiments, the target starting material comprises an end plate, and the at least one type of material is the material type of the end plate. In some embodiments, the die comprises at least one harder material than the target starting material. In some embodiments, the die comprises a high performing metal. In some embodiments, the target starting material is devoid of a high performing metal. In some embodiments, the high performing metal comprises stainless steel (e.g., 316), Inconel, titanium, tungsten, tool steel, platinum, rhodium, aluminum alloy, rhenium, carboncomposite, any plurality of types thereof, or any combination thereof. In some embodiments, the carbon composite comprises an allotrope of elemental carbon. In some embodiments, the supportive roller comprises (I) a harder material than that of the die and / or (III) a selfmending material. In some embodiments, the relative rotation of the die roller with respect to the supporting roller comprises rotation of the die roller in a first direction opposite to a section direction in which the supporting roller rotates. In some embodiments, (a) an absolute value of the rotation of the die roller is (e.g., substantially) the same as that of the supporting roller, (b) a lateral length of the die roller is (e.g., substantially) the same as that of the supporting roller, (c) a diameter of the die roller is (e.g., substantially) the same as that of the supporting roller, (d) a first lateral length of an engagement portion the die roller with the target starting material, is (e.g., substantially) the same as a second lateral length of an engagement portion the supporting roller with the target starting material. In some embodiments, (a) an absolute value of the rotation of the die roller is (e.g., substantially) the same as that of the supporting roller, (b) a lateral length of the die roller is different from that of the supporting roller, (c) a diameter of the die roller is different from that of the supporting roller, (d) a first lateral length of an engagement portion the die roller with the target starting material, is different from a second lateral length of an engagement portion the supporting roller with the target starting material. In some embodiments, different is smaller. In some embodiments, different is larger. In some embodiments, the die comprises an external surface and an opposing an internal surface, the internal surface of the die being operatively coupled with the internal roller to generate the die roller. In some embodiments, the die is configured to generate one or more components of an energy manipulation device (e.g., as disclosed herein). In some embodiments, the energy manipulation device comprises a battery (e.g., as disclosed herein). In some embodiments, the battery is a rechargeable battery (e.g., as disclosed herein). In some embodiments, the die is configured to cut battery cell components. In some embodiments, the product comprising an electrode, a counter electrode, a separator, or a divider, of the one or more battery cells. In some embodiments, a member of the product comprises a plurality of units having an aspect ratio of a length to a width of at least about 1:1 2:1, 4:1, 5:1, 8:1 , 10:1, 15:1 , 20:1, 50:1, 100:1, 1000:1 , or a higher aspect ratio. In some embodiments, in a member of the product comprises a plurality of units having an aspect ratio of a length to a height of at least about 1:1 2:1, 4:1, 5:1, 8:1, 10:1 , 15: 1 , 20: 1 , 50: 1 , 100: 1 , or a higher aspect ratio; and optionally wherein a battery of the battery cells comprises at least 1, 2, 10, 20, 50, 100, 150, 200, 250, or 500 cells.

[0014] In another aspect, a method of fabrication, the method comprising: executing one or more operations to process the target starting material at least in part by using any of the above devices. In some embodiments, processing the target material by the device is at least a portion of a manufacturing process including the product.

[0015] In another aspect, an apparatus for fabrication, the apparatus comprising: at least one controller configured for (a) operatively coupling with any of the above devices, and (b) executing, or directing at least one component of the device, to execute one or more operations associated with the fabrication. In some embodiments, the at least one controller is configured to operatively couple with a power source and / or with a communication platform. In some embodiments, the fabrication comprises manufacturing. In some embodiments, the manufacturing comprises roll to roll manufacturing. In some embodiments, the fabrication is of a system that includes the product. In some embodiments, the system comprises an energy manipulation device. In some embodiments, the energy manipulation device is a battery.

[0016] In another aspect, one or more non-transitory computer readable media comprising program instruction physically inscribed thereon, the program instructions, when read by one or more processors operatively coupled with any of the above devices, are configured to (I) execute, or direct execution of, one or more operations associated with fabrication of the product, (II) the one or more operations comprising directing at least one component of the device to execute the one or more operations. In some embodiments, the fabrication comprises manufacturing. In some embodiments, the manufacturing comprises roll to roll manufacturing. In some embodiments, the fabrication is of a system that includes the product. In some embodiments, the system comprises an energy manipulation device. In some embodiments, the energy manipulation device is a battery. In some embodiments, the device is configured for sequential (e.g., stepped) cutting and / or embossing of the target starting material. In some embodiments, the target staring material is sequentially (e.g., step by step) being cut by the device.

[0017] In another aspect, a method comprising: (a) providing any of the above devices, and (b) manufacturing, testing, storing, transporting, and / or using the device for fabrication of the product.

[0018] In another aspect, a system for effectuating the methods, operations of an apparatus, and / or operations inscribed by non-transitory computer readable program instructions (e.g., inscribed on a media / medium), disclosed herein.

[0019] In another aspect, a system for effectuating the methods, operations of an apparatus, operation of device(s), and / or operations inscribed by non-transitory computer readable program instructions (e.g., inscribed on a media / medium), disclosed herein.

[0020] In another aspect, device(s) (e.g., apparatus) for effectuating the methods, operations of an apparatus, and / or operations inscribed by non-transitory computer readable program instructions (e.g., inscribed on a media / medium).

[0021] In other aspects, systems, apparatuses (e.g., controller(s)), and / or non-transitory computer-readable program instructions (e.g., software) that implement any of the methodsdisclosed herein. In some embodiments, the program instructions are inscribed on at least one medium (e.g., on a medium or on media).

[0022] In other aspects, methods, systems, apparatuses (e.g., controller(s)), and / or non- transitory computer-readable program instructions (e.g., software) that implement any of the devices disclosed herein and / or any operation of these devices. In some embodiments, the program instructions are inscribed on at least one medium (e.g., on a medium or on media).

[0023] In another aspect, an apparatus comprises at least one controller that is configured (e.g., programmed) to direct a mechanism used in a methodology disclosed herein to implement (e.g., effectuate) any of the method and / or operations disclosed herein, wherein the controller(s) is operatively coupled with the mechanism. In some embodiments, the controller(s) implements any of the methods and / or operations disclosed herein. In some embodiments, the at least one controller comprises, or be operatively coupled with, a hierarchical control system. In some embodiments, the hierarchical control system comprises at least three, four, or five, control levels. In some embodiments, at least two operations are performed, or directed, by the same controller. In some embodiments, at least two operations are each performed, or directed, by a different controller.

[0024] In another aspect, an apparatus comprises at least one controller configured (e.g., programmed) to implement (e.g., effectuate), or direct implementation of the method, process, and / or operation disclosed herein. In some embodiments, the at least one controller implements any of the methods, processes, and / or operations disclosed herein.

[0025] In another aspect, non-transitory computer readable program instructions, when read by one or more processors, are configured to execute, or direct execution of, the method, process, and / or operation disclosed herein. In some embodiments, the at least one controller implements any of the methods, processes, and / or operations disclosed herein. In some embodiments, at least a portion of the one or more processors is part of a mechanism, outside of the mechanism, or in a location remote from the mechanism disclosed herein (e.g., in the cloud).

[0026] In another aspect, a system comprises an apparatus and at least one controller configured (e.g., programmed) to direct operation of the apparatus, wherein the at least one controller is operatively coupled with the apparatus. In some embodiments, the apparatus includes any apparatus or device disclosed herein. In some embodiments, the at least one controller implements, or direct implementation of, any of the methods disclosed herein. In some embodiments, the at least one controller directs any apparatus (or component thereof) disclosed herein. In some embodiments, at least two operations (e.g., instructions) of the apparatus are directed by the same controller. In some embodiments, at least two operations (e.g., instructions) of the apparatus are directed by different controllers. In some embodiments, at least two operations (e.g., instructions) are carried out by the sameprocessor and / or by the same sub-computer software product. In some embodiments, at least two of operations (e.g., instructions) are carried out by different processors and / or by different sub-computer software products.

[0027] In another aspect, a computer software product, comprising a (e.g., non-transitory) computer-readable medium / media in which program instructions are stored, which instructions, when read by a computer, cause the computer to direct a mechanism used to implement (e.g., effectuate) any of the method disclosed herein, wherein the non-transitory computer-readable medium is operatively coupled with the mechanism. In some embodiments, the mechanism comprises an apparatus or an apparatus component.

[0028] In another aspect, a computer system comprising one or more computer processors and non-transitory computer-readable medium / media coupled thereto. In some embodiments, the non-transitory computer-readable medium / media comprises machineexecutable code that, upon execution by the one or more computer processors, implements any of the methods and / or operations (e.g., as disclosed herein), and / or effectuates directions of the controller(s) (e.g., as disclosed herein).

[0029] In another aspect, a method comprises executing one or more operations associated with at least one configuration of the mechanism(s) (e.g., device(s)) disclosed herein.

[0030] In another aspect, an apparatus comprises at least one controller is configured (i) operatively couple to the device, and (ii) direct executing one or more operations associated with at least one configuration of the device(s) disclosed herein.

[0031] In another aspect, at least one controller is associated with the methods, devices, and software disclosed herein. In some embodiments, the at least one controller comprises at least one connector configured to connect to a power source. In some embodiments, the at least one controller being configured to operatively couple with a power source at least in part by (I) having a power socket and / or (II) being configured for wireless power transfer using inductive charging. In some embodiments, the at least one controller comprises a nonvolatile memory, e.g., a solid-state device (SSD) such as a FLASH memory. In some embodiments, the at least one controller is included in, or comprises, a hierarchical control system. In some embodiments, the hierarchical control system comprises at least three hierarchical control levels. In some embodiments, the at least one controller is included in a control system disclosed herein. In some embodiments, the at least one controller is configured to control at least one other component of a mechanism (e.g., system, device, or apparatus) disclosed herein. In some embodiments, the device disclosed herein is a component of a system, and wherein the at least one controller is configured to (i) operatively couple to another component of the system and (ii) direct operation of the other component. In some embodiments, the at least one controller is configured to directoperation of the other component at least in part for participation of the other component in a method disclosed herein.

[0032] In another aspect, non-transitory computer readable program instructions for a method disclosed herein, the non-transitory computer readable program instructions, when read by one or more processors operatively coupled with the device, cause the one or more processors to direct executing one or more operations associated with at least one configuration of the device(s) disclosed herein.

[0033] In some embodiments, the program instructions are of a computer product.

[0034] The various embodiments in any of the above aspects are combinable (e.g., within an aspect), as appropriate. Individual features (e.g., embodiments) disclosed herein are combinable in any manner requested and / or desired, as applicable.

[0035] Additional aspects and advantages of the present disclosure will become readily apparent to those skilled in this art from the following detailed description, wherein only illustrative embodiments of the present disclosure are shown and described. As will be realized, the present disclosure is capable of other and different embodiments, and its several details are capable of modifications in various obvious respects, all without departing from the disclosure. Accordingly, the drawings and description are to be regarded as illustrative in nature, and not as restrictive.INCORPORATION BY REFERENCE

[0036] All publications, patents, and patent applications mentioned in this specification are herein incorporated by reference to the same extent as if each individual publication, patent, or patent application was specifically and individually indicated to be incorporated by reference.

[0037] It should be appreciated that any patent, publication, or other disclosure material, in whole or in part, which is said to be incorporated by reference herein is incorporated herein only to the extent that the incorporated material does not conflict with existing definitions, statements, or other disclosure material set forth in this disclosure. As such, and to the extent necessary, the disclosure as explicitly set forth herein supersedes any conflicting material incorporated herein by reference. Any material, or portion thereof, that is said to be incorporated by reference herein, but which conflicts with existing definitions, statements, or other disclosure material set forth herein will only be incorporated to the extent that no conflict arises between that incorporated material and the existing disclosure material.BRIEF DESCRIPTION OF THE DRAWINGS

[0038] The present disclosure, in accordance with one or more various implementations, is described in detail with reference to the following drawings. The drawings are provided for purposes of illustration only and merely depict typical or example implementations. These drawings are provided to facilitate an understanding of the concepts disclosed herein andshould not be considered limiting of the breadth, scope, or applicability of these concepts. It should be noted that for clarity and ease of illustration, these drawings are not necessarily made to scale.

[0039] The novel features of the present disclosure are set forth with particularity in the appended claims. Each of the figures disclosed herein is shown in accordance with some implementations of the subject matter of the disclosure. A better understanding of the features and advantages of the present disclosure will be obtained by reference to the following detailed description that sets forth illustrative embodiments, in which the principles of the present disclosure are utilized, and the accompanying drawings or figures (also “Fig.” and “Figs.” herein), of which:

[0040] Fig. 1 depicts a schematic example of various cells;

[0041] Fig. 2 depicts schematic examples of folding options for energy manipulation device (e.g., battery) components, and a current collector;

[0042] Fig. 3 depicts schematic examples of energy manipulation devices (e.g., batteries) and cells;

[0043] Fig. 4 depicts schematic examples of cell architectures;

[0044] Fig. 5 depicts schematic exploded views of energy manipulation device (e.g., battery) components;

[0045] Fig. 6 depicts illustrative examples of energy manipulation device (e.g., battery) components;

[0046] Fig. 7 depicts images and exploded view of energy manipulation device (e.g., battery) components;

[0047] Fig. 8 depicts images of energy manipulation device (e.g., battery) components;

[0048] Fig. 9 depicts an illustrative example of a device (e.g., battery) and device components,

[0049] Fig. 10 depicts illustrative examples of a device (e.g., battery) components;

[0050] Fig. 11 depicts a perspective view of a portion of an end of a stacked cell;

[0051] Fig. 12 is an illustrative schematic perspective view of components of a rotary die assembly, e.g., for manufacturing electrodes of secondary batteries, in accordance with some implementations of the subject matter of the disclosure;

[0052] Fig. 13 depicts a perspective schematic view of structural framework of a rotary dicer;

[0053] Fig. 14 depicts a perspective schematic view of rotary dicer components;

[0054] Fig. 15 depicts a perspective schematic view of rotary dicer components;

[0055] Fig. 16 depicts schematic views of rotary dicer components;

[0056] Fig. 17 is an illustrative view of a rotary die, e.g., for manufacturing electrodes of secondary batteries, in accordance with some implementations of the subject matter of thedisclosure. Fig. 17 depicts various schematic views of a relief containing sheet (also referred to herein as “die”);

[0057] Fig. 18 is an illustrative perspective schematic view of a roller (e.g., a rotary magnetic chuck for manufacturing electrodes of secondary batteries), in accordance with some implementations of the subject matter of the disclosure;

[0058] Fig. 19 depicts a photographic image of a portion of a rotary dicer coupled with relief containing sheet (relief sheet utilized as a die);

[0059] Fig. 20 depicts a photographic image of a portion of a rotary dicer coupled with a relief containing sheet;

[0060] Fig. 21 is an illustrative photographic images showing example portions of relief containing sheet - die portions, e.g., for manufacturing electrodes of secondary batteries, in accordance with some implementations of the subject matter of the disclosure;

[0061] Fig. 22 is an illustrative flowchart of a process, e.g., for manufacturing electrodes of a secondary battery using a rotary die assembly, in accordance with some implementations of the subject matter of the disclosure;

[0062] Fig. 23 depicts a schematic example of a control system; and

[0063] Fig. 24 depicts a schematic example of a processing system.

[0064] The figures and components therein may not be drawn to scale. Various components of the figures described herein may not be drawn to scale.DETAILED DESCRIPTION

[0065] While various embodiments of the inventions have been shown, and described herein, it will be obvious to those skilled in the art that such embodiments are provided by way of example only. Numerous variations, changes, and substitutions may occur to those skilled in the art without departing from the invention. It should be understood that various alternatives to the embodiments of the invention described herein might be employed. The various embodiments disclosed herein are combinable, as appropriate.

[0066] Reference throughout the specification to “various embodiments,” “some embodiments,” “one embodiment,” “some example embodiments,” “one example embodiment,” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with any embodiment is included in at least one embodiment. Thus, appearances of the phrases “in various embodiments,” “in some embodiments,” “in one embodiment,” “some example embodiments,” “one example embodiment,” or “in an embodiment” in places throughout the specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures or characteristics may be combined in any suitable manner in one or more embodiments.

[0067] Terms such as “a,” “an” and “the” are not intended to refer to only a singular entity but include the general class of which a specific example may be used for illustration. Theterminology herein is used to describe specific embodiments in the present disclosure, but their usage does not delimit to the specific embodiments of the present disclosure. The term “includes” means includes but not limited to, the term “including” means including but not limited to, and the term “based on” means based at least in part on.

[0068] An immediately consecutive second feature to a first feature is devoid of another feature disposed therebetween, the features being of the same type. The feature can be a real-life feature, a calculated feature, or any other virtual feature.

[0069] When ranges are mentioned, the ranges are meant to be inclusive, unless otherwise specified. For example, a range between value 1 and value 2 is meant to be inclusive and include value 1 and value 2. The inclusive range will span any value from about value 1 to about value 2. The term “adjacent” or “adjacent to,” as used herein, includes “next to,” “adjoining,” “in contact with,” and “in proximity to.” When ranges are mentioned (e.g., between, at least, at most, and the like) the endpoint(s) of the range is / are also claimed. For example, when the range is from X to Y, the values of X and Y are also claimed. For example, when the range is at most Z, the value of Z is also claimed. For example, when the range is at least W, the value of W is also claimed.

[0070] The conjunction “and / or” as used herein in “X and / or Y” - including in the specification and claims - is meant to include the options (i) X, (ii) Y, and (iii) X and Y, as applicable. The phrase “including X, and / or Y” is meant to have the same meaning as the phrase “comprising X or Y” under currently prevailing US law.

[0071] The term “operatively coupled,” “operatively configured,” or “operatively connected” refers to a first mechanism that is coupled (or connected) to a second mechanism to allow the intended operation of the second and / or first mechanism. The coupling may comprise physical or non-physical coupling. The non-physical coupling may comprise signal-induced coupling (e.g., wireless coupling).

[0072] The phrase “is / are structured” or “is / are configured,” when modifying an article, refers to a structure of the article that can bring about the referred result.

[0073] The symbol “*” designates the mathematical operation of multiplication, e.g., “times.”

[0074] Fundamental length scale (abbreviated herein as “FLS”) comprises any suitable scale (e.g., dimension) of an object. For example, an FLS of an object may comprise a length, a width, a height, a diameter, a spherical equivalent diameter, a diameter of a bounding circle, a diameter equivalent of a bounding sphere.

[0075] A central tendency as understood herein comprises mean, median, or mode. The mean may comprise a geometric mean.

[0076] Performing a reversible first operation is understood herein to mean performing the first operation and being capable of performing the opposite operation to that first operation (e.g., which is a second operation). For example, when a controller directs reversiblyopening a shutter, that shutter can also close, and the controller can optionally direct a closure of that shutter. For example, when an attractor reversibly binds to a charge carrier, that attractor can also release that charge carrier after its binding.

[0077] While the disclosure refers to a cathode as an electrode, the electrode may be an anode, as applicable.

[0078] While various portions herein may refer for simplicity to a battery as an energy manipulation device, that disclosure is extended to any another energy manipulation device, as applicable. As noted herein, implementations of the present disclosure can relate to (e.g., secondary) batteries, the structures that make up the (e.g., secondary) batteries, and the methods and processes for manufacturing the structures and batteries. As used herein, the term “anode” used in the context of a (e.g., secondary) battery may refer to the negative electrode in a (e.g., secondary) battery.

[0079] "Anode" as used herein in the context of a secondary battery refers to the negative electrode in the secondary battery. "Cathode" as used herein in the context of a secondary battery refers to the positive electrode in the secondary battery.

[0080] “Anode material” or “anodically active” as used herein may refer to a material or materials suitable for use as the negative electrode of a (e.g., secondary) battery. The term “cathode” as used herein in the context of a (e.g., secondary) battery may refer to the positive electrode in a (e.g., secondary) battery. “Cathode material” or “cathodically active” as used herein may refer to a material or materials suitable for use as the positive electrode of a (e.g., secondary) battery.

[0081] In some implementations described herein, the term “electrode” may be used to refer to either the anode or the cathode, and the term “counter-electrode” may refer to the other or opposite. For the sake of explanation, implementations may be described in terms of “electrode” and “counter-electrode.” It should be appreciated that in these implementations, the term electrode may be replaced by the term anode while the term counter-electrode may be replaced by the term cathode, as applicable. Alternatively, in these implementations, the term electrode may be replaced by the term cathode while the term counter-electrode may be replaced by the term anode, as applicable.

[0082] In some embodiments, the energy manipulation device may comprise at least one battery. The battery may comprise one or more cells. The battery may be a rechargeable battery, e.g., a secondary battery. The charge carriers of the battery may comprise alkali earth, alkali cations, a plurality of types of any thereof, or any combination thereof. In an example, the battery comprises charge carriers such as lithium charge carriers.

[0083] In some embodiments, the energy manipulation device may comprise at least one battery. The battery may comprise one or more cells. The battery may be a rechargeable battery, e.g., a secondary battery. The charge carriers of the battery may comprise alkaliearth, alkali cations, a plurality of types of any thereof, or any combination thereof. In an example, the battery comprises charge carriers such as lithium charge carriers. In some embodiments, charge carriers may comprise carrier ions. In some embodiments, carrier ions are provided to positive electrodes and / or negative electrodes by carrier ion supply layers. Carrier ion supply layers may comprise one or more sources of lithium ions, sodium ions, potassium ions, calcium ions, magnesium ions, aluminum ions, and / or similar such ions. The battery may or may not be a polymer type battery such as a lithium polymer type battery.

[0084] In some embodiments, the energy manipulation device includes at least one unit cells. The energy manipulation device may comprise a population of unit cells (e.g., also referred to herein as a “set of cells”). The energy manipulation device may comprise an electrode connector operatively coupled with the electrode and a counter-electrode connector operatively coupled with the counter-electrode, with operatively coupled comprising electrically connected. The electrode connector may be also referred to herein as “an electrode terminal,” and the counter-electrode connector may be also referred to herein as “a counter-electrode terminal.” The energy manipulation device may comprise an electrode busbar, a counter-electrode busbar, an electrode terminal operatively coupled with the electrode busbar, and a counter-electrode terminal operatively coupled with the counterelectrode busbar. The electrode and counter electrode of the unit cell are separated by each other by a gap, e.g., to electrically separate the electrode from the counter-electrode. The gap may include a separator configured to (a) electrically isolate the electrode from the counter electrode and (b) allow traversal of charge carriers through the separator. In some embodiments, each unit cell of the set of cells, includes an electrode structure and a counter-electrode structure separated from each other by a gap. One or more (e.g., each) cells of the set of cells, each include a separator disposed in the gap. In some embodiments, the battery includes adjacent electrode sub-units. Each of the electrode sub-units has a dimension in the X-axis, Y-axis and Z-axis, respectively. The X-axis, Y-axis and Z-axis are each mutually perpendicular, akin to a Cartesian coordinate system. As used herein, dimensions of each electrode sub-unit in the Z-axis may be referred to as a "height", dimensions in the X-axis may be referred to as a "length" and dimensions in the Y-axis may be referred to as a "width." The electrode sub-units may be combined into one or more unit cells. A cell can include (a) at least one anodically active material mass (e.g., layer) and / or (b) at least one cathodically active material mass (e.g., layer). In some embodiments, the anodically active material is separated from the cathode by the gap. In some embodiments, the cathodically active material is separated from the anode by the gap. In some embodiments, the cathodically active material is separated from the anodically active material by the gap. The set of cells may comprise at least 2, 10, 20, 50, 100, 150, 200, 250, or 500 cells. The set of cells may comprise any number of cells between the aforementionednumber of cells, e.g., from 2 to 500 cells, or from 50 to 500 cells. An active material mass may operatively couple to a current collector. The active material mass may comprise one or more layers. The active material may form a gradient

[0085] In some embodiments, the energy manipulation device includes an electrode busbar and a counter-electrode busbar. The electrode busbar can be operatively coupled with (e.g., electrically connected with) the electrode, e.g., via electrode tab. The counter-electrode busbar is operatively coupled with (e.g., electrically connected with) the counter-electrode, e.g., via counter-electrode tab. The electrode busbar can be operatively coupled with the electrodes of the set of cells, e.g., via electrode tabs. The counter-electrode busbar is operatively coupled with the counter-electrodes of the set of cells, e.g., via counter-electrode tabs. An electrode tab can be an extension of the electrode that is devoid of the electrode active material. A counter-electrode tab can be an extension of the counter-electrode that is devoid of the counter-electrode active material.

[0086] In some embodiments, the energy manipulation device includes a first busbar and a second busbar that are in electrical contact with the anode(s) and the cathode(s), respectively, e.g., via electrode tabs. The electrode tabs on the first side of the stack of cells can be electrically coupled with the first busbar, which may be referred to as an anode busbar. The electrode tabs on the second side of the stack of cells may be electrically coupled with the second busbar, which may be referred to as a cathode busbar. In some embodiments, the first busbar is electrically coupled with a first electrical terminal of the secondary battery, which is electrically conductive. When the first busbar comprises an anode busbar for the energy manipulation device (e.g., battery), the first electrical terminal comprises a negative terminal. In some embodiments, the second busbar is electrically coupled with a second electrical terminal of the energy manipulation device, which is electrically conductive. When the second busbar comprises a cathode busbar for the energy manipulation device, the second electrical terminal comprises a positive terminal of the energy manipulation device.

[0087] In some embodiments, the cell may be coupled with a (e.g., solid) busbar. In some embodiments, the set of cells may be coupled with the (e.g., solid) busbar. The busbar may comprise a (e.g., solid) material of a class. The material class may include an elemental metal, a metal alloy, or an allotrope of elemental carbon, any plurality of types thereof, or any combination thereof. The busbar may comprise (e.g., solid) material, e.g., including one or more types of materials. At least two types of materials may belong to the same class of materials. At least two types of materials may belong to different classes of materials. A class of material may be a composite or a non-composite material. A class of material may be a tacky material (e.g., a tacky connector), or a solid material (e.g., that is non-tacky). A class of material may be a material that is fluid, or non-fluid, e.g., during manufacture of theenergy manipulation device such as a battery. In an example, the (e.g., solid) busbar may comprise a metal alloy and an elemental metal. In an example, the (e.g., solid) busbar may comprise two types of metal alloys. In an example, the (e.g., solid) busbar may comprise a composite material and a non-composite material. The busbar may comprise any conductive material disclosed herein. In an example, the busbar includes copper (e.g., Cu101) and Inconel (e.g., N178). The material class can be an oxygen free material. The material class may be an electronic grade material.

[0088] In some embodiments, a busbar is attached to the current collector tabs, e.g., the attachment being assisted by the tacky connector. In an example, the busbar contacts the tacky connector that contacts the tab(s). The busbar may have a cross section of a Euclidean shape, e.g., a vertical cross section. The busbar may have a cross section of a geometric planar shape, e.g., a vertical cross section. The shape may include a polygon, an ellipse, a combination thereof and / or a plurality thereof. The polygon may include a rectangle, or a plurality of rectangles. In an example, a vertical cross section of the busbar is a rectangle. In an example, the vertical cross section of the busbar comprises at least two different types of shapes, e.g., rectangles. In an example, the vertical cross section of the busbar comprises at least two types of shapes that are (e.g., substantially) the same, and that are distinct from each other. The two types of shapes may comprise the same type of material or may each be from a different type of material. The two types of shapes may comprise the same class of material or may each be from a different class of material. Two of the shapes may be separated from each other by a gap. Two of the shapes may contact each other. A cross section of the busbar may comprise an indentation, e.g., a depression. The depression may be configured to accommodate (a) folded tab(s) (b) any tacky connector, (c) any welding, or (d) any combination thereof. The depression may be configured to increase adhesion of the tab to the (e.g., solid) busbar. The increased adhesion may be at least in part by increasing the (e.g., solid) busbar’s adhesion to (i) any tacky connector and / or (ii) any welding. A contacting surface of the busbar is an exposed surface of the busbar face(s) configured to contract the (a) the tab(s), (b) any tacky connector, (c) any welding, or (d) any combination thereof. The contacting surface may undergo surface treatment before the contact. The surface treatment may be configured to increase adhesion between the (e.g., solid) busbar and (a) the tab(s), (b) any tacky connector, (c) any welding, or (d) any combination thereof. The surface treatment may comprise roughening of the contacting surface. The surface treatment may comprise etching, scraping, or printing (e.g., 3D printing). The surface treatment may comprise mechanical treatment type, chemical treatment type, any plurality thereof, or any combination thereof. The (e.g., solid) busbar may comprise one or more perforations (e.g., holes). The perforation(s) may be configured to accommodate dimensionality changesoccurring in the cell, e.g., during charging and / or discharging. The dimensionality changes of the cell may occur during its (e.g., normal) operation, testing, maintenance, storage, shipping, or any combination thereof.

[0089] In some embodiments, the cell undergoes pre-loading with charge carriers, e.g., before its regular use. The pre-loading may comprise loading the cell with charge carriers, e.g., “pre-lithiation” in the case of lithium cations being the charge carriers. The pre-loading (also referred herein as “buffering”) may be performed during manufacturing and / or before providing the battery for its intended use. The pre-loading may facilitate insertion of additional charge carriers for a charge carrier source such as a lithium source, into the electrode(s) of the battery such as into the anode(s). The electrode may be a vertically short electrode. The pre-loading may replenish (e.g., irreversible) loss of the charge carriers during formation of the battery, e.g., to increase (a) efficiency of the first cycle and / or (b) cell capacity. The pre-loading may result in a reservoir of the charge carriers within the cell, and / or smaller cycled voltage window. The pre-loading may improve current distribution, e.g., during fast charge. The pre-loading may improve the cycle life of the battery. Buffering or pre-loading may result in pressurization of the cell at its first charging cycle, e.g., due to loading of the anode with charge carriers such as lithium. The pressure adjuster described herein can aid in maintaining overpressure in the system without having to put pressure during buffering, e.g., the adjuster can establish a minimal / threshold overpressure in the energy manipulation device during formation without having to buffer the cell. A rough exposed surface of charge carrier plating may remain throughout the life of the battery, and may compromise function of the battery, e.g., due to depletion of charge carriers and / or due to causing a short (e.g., as a consequence of dendrite formation from an electrode to its counter electrode). In some examples, the geometry of a battery may include a side gap located adjacent to a cell, to enable electrolyte to flow into the gap during buffering.

[0090] In some embodiments, a cell comprises an electrode (e.g., reference electrode), a counter electrode, separated from each other by a gap, also referred to herein as “a separation space.” The separation space may comprise a separator, e.g., having a material comprising conduits or pores, e.g., micro conduits, or micropores. The pores and / or conduits may be configured to facilitate charge carriers (e.g., ions) to propagate through the separator. The conduits may be channels. Pores of the separator may form the conduit. The battery cell may comprise, or may be coupled with, an insulator. The battery cell may comprise, or may be coupled with, a dividing space. At least one component may be electrically insulating, e.g., the separator body, the insulator, or at least one component of the dividing space. The dividing space and the separating space may or may not have the same material content. A divider material may be disposed in the dividing space. The dividing material may or may not be of the same type of material as the separator. Theseparator may be (e.g., substantially) a plane, or a layer. The separator may be an ionically permeable microporous material suitable for use as a separator in an electrochemical cell. In some embodiments, the separator layer is coated with ceramic particles on one or both sides. In some embodiments, a cell includes an anode current collector in the center, which may comprise or be electrically coupled with, one of the electrode tabs on one of the sides of the secondary battery. In some implementations, the unit cell includes the anodically active material layer, the separator layer, the cathodically active material layer, and a cathode current collector in a stacked formation along a stacking axis. The cathode current collector may comprise a cathode tab devoid of cathode active material. The anode current collector may comprise an anode tab devoid of anode active material. The anode tab may be disposed at the same side of the cathode tab, or at a different side such as an opposing side.

[0091] In some embodiments, the cathode includes cathodically active material. The cathodically active material may include a cathodically active material including transition metal oxides, transition metal sulfides, transition metal nitrides, lithium-transition metal oxides, lithium-transition metal sulfides, lithium-transition metal nitrides, any plurality thereof, and / or any combination thereof. The cathodically active material may include transition metal elements of the transition metal oxides, transition metal sulfides, transition metal nitrides, any plurality thereof, and / or any combination thereof. The cathodically active material may include metal elements having a d-shell or f-shell. The cathodically active material may comprise metal element including Sc, Y, lanthanoids, actinoids, Ti, Zr, Hf, V, Nb, Ta, Cr, Mo, W, Mn, Tc, Re, Fe, Ru, Os, Co, Rh, Ir, Ni, Pb, Pt, Cu, Ag, Au, any plurality thereof, and / or any combination thereof. The cathodically active material may include lithium cobalt oxide (UCOO2), LiNio.5Mn1.5O4, Li(NixCoyAlz)O2, lithium metal phosphate (e.g., lithium iron phosphate, LiFePO4), Li2MnO4, V2O5, molybdenum oxysulfides, phosphates, silicates, vanadates, sulfur, sulfur compounds, oxygen (air), lithium nickel manganese cobalt oxide (Li(NixMnyCoz)O2), any combinations thereof, and / or any plurality thereof. In some implementations, the cathode (e.g., cathodically active material) is selected from transition metal oxides, transition metal sulfides, transition metal nitrides, lithium-transition metal oxides, lithium-transition metal sulfides, transition-metal phosphates, lithium-transition-metal phosphates, and lithium-transition metal nitrides may be selectively used. The transition metal elements of these transition metal oxides, transition metal sulfides, and transition metal nitrides can include metal elements having a d-shell or f-shell. Specific examples of such metal element 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, LiNio.5Mn1.5O4, Li(NixCoyAlz)O2, LiFePO4, Li2MnO4, V2O5, molybdenum oxysulfides, phosphates, silicates, vanadates, sulfur, sulfur compounds,oxygen (air), Li(NixMnyCoz)O2, and combinations thereof. The cathode active material may comprise, S (e.g., U2S in the lithiated state), LiF, Fe, Cu, Ni, FeF2, FeOdF3.2d, FeFs, C0F3, C0F2, C11F2, NiF2, where 0<d<0.5, metal oxides, metal sulfides, metal phosphates, binders, fillers, any plurality thereof, or any combination thereof. The filler may be inert to the chemistry of the energy manipulation device, e.g., chemistry of the cell. The binders may include polyvinylidene difluoride and / or polytetrafluoroethylene. The cathode may comprise Lithium Cobalt Oxide (LCO), Nickel Manganese Cobalt (NMC), Lithium iron phosphate (LFP), lithium manganese oxide (LMO), Nickel, Lithium manganese Iron phosphate, lithium manganese iron phosphate, sodium-ion, nickel, manganese rich lithium, lithiated cobalt oxide, lithiated manganese oxide, lithiated nickel-manganese-cobalt oxide, any plurality of types thereof, or any combination thereof. The cathode (e.g., and the energy manipulation device) may be devoid of cobalt.

[0092] In some embodiments, the energy manipulation device may comprise a battery. The energy manipulation device may comprise Li-ion batteries, nickel metal hydride batteries, alkaline batteries, any plurality of types thereof, or any combination thereof. The battery may include a cell comprising Cu, Al, Ni, polyethylene, polypropylene, any derivatives thereof, any plurality of types thereof, or any combination thereof.

[0093] In some embodiments, the anode includes anodically active material. The anodically active material may include silicon (Si), germanium (Ge), tin (Sn), lead (Pb), antimony (Sb), bismuth (Bi), zinc (Zn), aluminum (Al), titanium (Ti), nickel (Ni), cobalt (Co), cadmium (Cd), any combination thereof, and / or any plurality thereof. The anodically active material may include alloys or intermetallic compounds including Si, C, Ge, Sn, Pb, Sb, Bi, Zn, Al, Ti, Ni, Co, Cd, any combination thereof, and / or any plurality thereof. The anodically active material may include alloys, intermetallic compounds. The anodically active material may include oxides, carbides, nitrides, sulfides, phosphides, selenides, tellurides of Si, Ge, Sn, Pb, Sb, Bi, Zn, Al, Ti, Fe, Ni, Co, V, or Cd, any combination thereof, or any plurality thereof. The anodically active material may include mixtures (e.g., containing Lithium), composites (e.g., containing Lithium), any combination thereof, and / or any plurality thereof. The anodically active material may include salts (e.g., of Sn), hydroxides (e.g., of Sn), lithium titanate, lithium manganate, lithium aluminate, lithium-containing titanium oxide, lithium transition metal oxide, ZnCo2O4, particles of graphite, particles of carbon, metal form of the charge carriers (e.g., lithium metal), any combinations thereof, and / or any plurality thereof. The anodically active material may be coated. The coating may comprise stabilized metal form of the charge carrier material (e.g., lithium metal particles). The particulate material may include lithium carbonate-stabilized lithium metal powder, lithium silicate stabilized lithium metal powder, other source of stabilized lithium metal powder or ink, any combination thereof, and / or any plurality thereof. The anode active material may comprise a materialintercalating the charge carriers. The active material of the anode may include silicon and / or an allotrope of elemental carbon. The allotrope of elemental carbon may be any of the ones disclosed herein, e.g., active carbon, graphite, carbon fiber, carbon nanotube, amorphous carbon, and / or a fullerene. The tubular structures may comprise nested tubes, e.g., at least 2, or 3 nested tubes. The carbon fibers may be weaved, aligned (e.g., in parallel and / or at an angle relative to each other), randomly situated, or any combination thereof, as applicable. The anode may be a 100% silicon - carbon anode. The anode may comprise particulate material. The anode may comprise a carbon scaffold on which silicon is deposited (e.g., layer of silicon). An exposed surface of the silicon may be coated by the, or by at least one other, of the allotropes of elemental carbon. The carbon may comprise black carbon. The carbon may include hard carbon and / or soft carbon. The carbon-silicon structure may comprise successive layers and / or scaffold. The carbon may comprise a particulate material. The particulate material may serve as a base for deposition of the one or mor layers. The particulate material may or may not include crevices. The one or more layers may be deposited onto an exposed surface of the crevices. Anodically active materials may comprise carbon materials such as graphite and soft or hard carbons, or graphene (e.g., single-walled or multi-walled carbon nanotubes), or any of a range of metals, semi-metals, alloys, oxides, nitrides, compounds capable of intercalating lithium, compounds forming an alloy with lithium, any plurality thereof, or any combination thereof. Specific examples of the metals or semi-metals that may be used as the anode material include graphite, tin, lead, magnesium, aluminum, boron, gallium, silicon, Si-C composites, Si / graphite blends, silicon oxide (SiOx), porous Si, intermetallic Si alloys, indium, zirconium, germanium, bismuth, cadmium, antimony, silver, zinc, arsenic, hafnium, yttrium, lithium, sodium, graphite, carbon, lithium titanate, palladium, mixtures thereof, any plurality thereof, or any other combination thereof. In some implementations, the anodically active material may comprise aluminum, tin, silicon, an oxide thereof, a nitride thereof, a fluoride thereof, other alloy thereof, any plurality thereof, or any combination thereof. In some implementations, the anodically active material may comprise silicon, an alloy thereof, a composite thereof, an oxide thereof, any plurality thereof, or any combination thereof. In some embodiments, the battery may be without an active material (e.g., simple galvanic cell).

[0094] In some embodiments, the energy manipulation device comprises an electrochemical cell. The cell may comprise an electrode and a counter-electrode separated from each other by a gap. The energy manipulation device may comprise a simple galvanic cell, e.g., comprising passive electrodes. The galvanic cell may comprise anode current collector, cathode current collector separated from the anode current collector by a gap, an electrolyte, and charge carriers. The cell may comprise partially active electrodes - one current collector contacting an active material mass. The mass can be a layer. The cell may comprise fullyactive electrodes - both electrode and counter-electrode current collectors of the cell, each contacting a respective active material mass, e.g., a layer.

[0095] In some examples, the energy manipulation device may comprise a fuel cell. In other examples, the energy manipulation device may comprise a primary battery, which may be a non-rechargeable battery. The primary battery may be a battery comprising Li metal, alkaline, zinc-carbon, silver-oxide, and / or any other suitable material. In some examples, the energy manipulation device may comprise a secondary battery, which may be rechargeable. The secondary battery may be a battery comprising Li ion, lead acid (lead dioxide with sulfuric acid), nickel cadmium, nickel metal hydride, and / or any other suitable material. The use of a secondary battery or rechargeable battery may enable a reduction in environmental waste, as the materials may be reused for multiple cycles as compared to a primary or non- rechargeable battery. In some examples, the energy manipulation device described herein may comprise an electrochemical cell. As noted above, the cell may include an anode material and a cathode material. In an example, an electrochemical cell comprises passive electrodes, wherein the simple electrochemical cell includes an anode charge carrier, a cathode charge carrier separated from the anode by a gap, an electrolyte and charge carriers. In some examples, the energy manipulation device may comprise one or more active electrodes, wherein one charge carrier is in contact with an active material mass. The active material mass can comprise (e.g., be deposited in a form of) a layer. In some examples, the energy manipulation device may comprise one or more fully active electrodes, wherein the electrode and / or counter electrode charge carriers of a cell each contact a respective active material mass, e.g., a layer. The active material mass is configured to operatively coupled with its respective current collector of the electrode. The current collector may have an electrical conductivity of at least about 103Siemens / cm (S / cm), 104S / cm, 105S / cm, or 106S / cm. The current collector may have an electrical conductivity between any of the aforementioned values, e.g., from about 103S / cm to about 106S / cm, or from about 105S / cm to about 106S / cm.

[0096] In some examples, the cell comprises an active material, a charge carrier, an electrolyte, any plurality of types thereof, or any combination thereof. The active material (e.g., mass such as layer) may be added to one side or to both sides of a cell or cell stack. In some embodiments, the electrode comprises a current collector (e.g., conductor) comprising elemental metal, metal alloys, an allotrope of elemental carbon, any plurality of types thereof, or any combination thereof. The allotrope of elemental metal may comprise graphite, carbon nanotubes, carbon wires, fullerenes, hard carbon, soft carbon, any plurality of types thereof, or any combination thereof. The cell may comprise charge carriers comprising salts such as lithium salts. The electrolyte material may comprise solid, semi-solid, liquid, any plurality of types thereof, or any combination thereof. The electrolyte materials may includesalts, acids, and / or bases, e.g., dissolved in non-aqueous polar solvent(s). In some embodiments, the electrolyte may comprise a polymer-based electrolyte. The polymer-based electrolyte may include PEO-based polymer electrolyte, polymer-ceramic composite electrolyte, polymer-ceramic composite electrolyte, polymer-ceramic composite electrolyte, and / or similar such electrolytes. In some embodiments, the electrolyte may include an oxidebased electrolyte (e.g., lanthanum titanate (Lio.34Lao.56TiO3), Al-doped lithium lanthanum zirconate (Li6.24La3ZrzAlo.24011.98), Ta-doped lithium lanthanum zirconate (Li6.4La3Zri.4Tao.6012), lithium aluminum titanium phosphate (Lit.4Alo.4Tit.6(PO4)3), and / or similar such electrolytes. In some embodiments, the electrolyte may comprise a solid electrolyte (e.g., sulfide-based electrolyte such as lithium tin phosphorus sulfide (LiioSnP2Si2), lithium phosphorus sulfide (13-U3PS4), lithium phosphorus sulfur chloride iodide (Li6PS5C1o.91o.i), and / or similar such electrolytes. The electrolyte may comprise ethylene carbonate, diethylcarbonate, dimethylcarbonate, ethylmethylcarbonate, propylene carbonate, any derivatives thereof, or any combination thereof.

[0097] Fig. 1 shows in example 100 a schematic representation of a cell, the cell comprising an electrode 102a - “C” (e.g., a cathode), and an opposing electrode which is a counter electrode 105a - “A” (e.g., an anode). A separator is disposed in separator space (e.g., gap) 103 - “B.” The battery cell is disposed in a battery having housing 109. The housing can be rigid, or flexible. The housing may include a rigid portion and / or a flexible portion. The battery can optionally have an insulator 104. The insulator may comprise one or more materials comprising a ceramic, a polymer, or a resin. The battery may comprise one or more insulator types. In an example, a polymer may fill a cathode gap, and alumina fills a cathode gap, the gap being from the edge of the cell to its immediately adjacent edge of the case (also herein “casing”). In some embodiments, insulator may comprise a non-electrically conductive material. The ceramic may comprise alumina (AI2O3), zirconia (ZnCh), magnesium oxide (MgO), boron nitride (BN), mullite, boehmite, or silicon carbide (SiC, e.g., in pure form). Under normal conditions during use of the battery, the main current is a load current 106 passing from one electrode to its opposing electrode, and through separation space 103. When volume 104 comprises the insulator, the insulator contacts at least at opposing sides 102b and 102c of electrode 102a and at opposing sides 105b and 105c of counter-electrode 105a.

[0098] Fig. 1 shows in example 110 a schematic representation of a cell, the cell comprising an electrode 112 - “C” (e.g., a cathode), and an opposing electrode which is a counter electrode 115 - “A” (e.g., an anode). A separator is disposed in separator space 113 - “B.” The battery cell is disposed in a battery having housing 119. The separation space extends 121 beyond electrode 112, and extends 122 beyond counter electrode 115, the extension being along a long axis of each of the electrode, the long axis depicted in Fig. 1. Theextension can extend longer in the lateral direction. The extension can form the tab. The battery has an insulator 114. Under the normal conditions, the load current 116 may be passing through separation space 113.

[0099] In some embodiments, the different extension distances of the components of the cell in the lateral direction, form a corrugated (e.g., misaligned) face of the cell, and thus a set of the cells, e.g., as depicted in Fig. 1 , 120 for a cell. The cell can comprise at least one uneven side, e.g., as is depicted in Fig. 1 , 120. The uneven (e.g., misaligned) side can create a wavy side of a set of cells.

[0100] Fig. 2 shows a schematic example 200 of a current collector in the form of a film or strip. The electrode active material may contact (e.g., be deposited onto) a conductive sheet, e.g., having a thickness of at most about 6 millimeters (mm), 5mm, 2.5mm, 1mm, or 0.5mm. The conductive sheet may be a foil, e.g., having a thickness of at most about 0.4mm, 0.2 mm, or 0.1mm. The current collector may comprise an internal portion, e.g., when assembled in the battery. The internal portion of the current collector contacts the active material of the electrode. The tab may be (e.g., substantially) devoid of the electrode active material. The current collector has a length axis and a width, and a height. The current collector has a face type having a largest surface area, the face type including sections 201, and 202. The current collector has a length 203, a width 204, and a height 205. Section 202 designates the tab of the current collector that can bend upon assembly of the energy manipulation device such as to couple with a busbar, and section 201 designates the planar section of the current collector that can couple to an electrode active material, e.g., a powder with binder(s) and / or filler(s). In the example shown in 200, the tabs assume the same width 204 along their length. In some embodiments, the tabs contract (e.g., narrow such as taper) along their length, e.g., and along the longest axis 211. Longest axis 211 of the current collector intersects position 214 on a face of the electrode having height 205 and width 204, which face has the smallest surface area in the example of 200. The current collector has a shorter axis 212 normal to axis 211. The contraction of the tabs along axis 211 may be symmetrical about axis 211 , e.g., using a mirror symmetry, the mirror being along axis 211.

[0101] In some embodiments, the current collector may be an anode current collector. In some embodiments, the current collector may be a cathode current collector. The anode current collector may comprise a conductive material such as copper, carbon, nickel, stainless-steel, cobalt, titanium, and tungsten, and alloys thereof, or any other material suitable as an anode current collector layer. The current collector has an electrical conductivity of at least about 103 Siemens / cm, 104 Siemens / cm, or 105 Siemens / cm. The current collector has an electrical conductivity between any of the aforementioned values, e.g., from about 103 Siemens / cm to about 105 Siemens / cm. The cathode current collector may comprise aluminum, nickel, cobalt, titanium, and tungsten, or alloys thereof, or anyother material suitable for use as a cathode current collector layer. In some embodiments, the cathode current collector comprises a metal such as aluminum, carbon, chromium, gold, nickel, NiP, palladium, platinum, rhodium, ruthenium, an alloy of silicon and nickel, titanium, or a combination thereof. In an example, a cathode current collector comprises gold or an alloy thereof such as gold silicide. By way of further example, in one embodiment, a cathode current collector comprises nickel or an alloy thereof such as nickel silicide.

[0102] Fig. 2 shows in example 250, a schematic vertical cross section of various batteries, showing arrangement and / or folding of battery cells with respect to a Cartesian coordinate system. In example 251, battery cells are arranged parallel to each other. Examples 252-255 show various folding of a sheet comprising one or more battery cells, with 252 showing a zigzag fold, 253 showing a top hat fold, 254 showing a sinusoidal type fold, 255 showing a spiral (e.g., rolling) fold, and 256 an oval or oblong spiral (e.g., rolling) fold. The battery may comprise a battery cell folded in a wound (e.g., jelly roll) configuration having an oblong or cylindrical configuration, e.g., as shown in Fig. 3, 350.

[0103] In some embodiments, one or more cells are disposed within a housing to form the energy manipulation device, e.g., battery. The housing may insulate the battery from one or more reactive agents (also referred to herein as “reactive species”) present in the ambient environment external to the energy manipulation device. The reactive agent(s) may comprise oxygen, water, alcohol, thiol, sulfuric acid, phosphoric acid, carboxylic acid, hydrogen sulfide, any plurality thereof, or any combination thereof. The reactive agent(s) may be oxygen based, sulfur based, and / or phosphorous based. The reactive agent(s) may include water and / or oxygen. In an example, the reactive agent(s) comprise water in a liquid and / or vapor form. The water may be in the form of droplets. The housing may be configured to separate and / or insulate the cell(s) from the reactive agent(s) present in the ambient environment external to the energy manipulation device, e.g., to curtail (e.g., hinder, or prevent) reactive agent(s) from reaching the cell such as including reaching the electrode(s).

[0104] The energy manipulation device is of a (e.g., Euclidean) three-dimensional (3D) geometric shape. The energy manipulation device may have an asymmetrical shape, e.g., its housing may be asymmetrical in shape. The Euclidean 3D shape may comprise a cylinder or a prism. The prism may be a Euclidean prism, or an amorphous prism. In some embodiments, the battery is a prismatic battery. In some embodiments, the battery is a cylindrical battery. The battery may have a first FLS such as a height (e.g., Fig. 4, 431) of at least about 1 millimeter (mm), 2mm, 3mm, 5mm, 6mm, 8mm, or 10mm. The first FLS of the battery may be of any value between the aforementioned values, e.g., from about 1mm to about 10mm. The battery may have a second FLS such as a length (e.g., Fig. 4, 432) of at least about at least about 10 millimeters (mm), 30mm, 40mm, 50mm, 70mm, 80mm, 100mm, 150mm, or 200mm. The battery may have a third FLS such as a width (e.g., Fig. 4,433) of at least about at least about 10 millimeters (mm), 30mm, 40mm, 50mm, 70mm, 80mm, 100mm, 150mm, or 200mm. The third FLS of the battery may be of any value between the aforementioned values, e.g., from about 10mm to about 200mm. The battery may have an aspect ratio of the second FLS to the first FLS of at least about 1:1 2:1, 4:1, 5: 1 , 8: 1 , 10:1 , 15: 1 , 20: 1 , 25: 1 , 30: 1 , 35: 1 , 50: 1 , or 100: 1. The battery may have an aspect ratio of the second FLS to the first FLS between the aforementioned values, e.g., from about 1 : 1 to about 10:1, from about 1 : 1 to about 50: 1 , from about 1 : 1 to about 100: 1 , or from about 2:1 to about 50:1. The FLS (e.g., from the first FLS and second FLS) may comprise a length, a width, a height, a diameter, or any other FLS such as disclosed herein.

[0105] Fig. 3 shows an example of vertical cross sections of various batteries with respect to a Cartesian coordinate system, viewed from a side having a length and a height (e.g., Fig. 4, height 451 and length 452). Example 300 shows battery cells such as cell 302 stacked in a direction normal to the z axis, the battery having housing 301. During a charge and discharge cycle, the battery expands and contracts. The expansion creates a force in the battery in a direction perpendicular to the stacking direction of the cells and towards the edges of the battery, e.g., along arrows 303. Constraints 307a and 307b are coupled with the cell stack to curb such expansion, e.g., anisotropic constraint configured to deter expansion in the direction of the arrows 303. The constraints 307a-b are disposed (e.g., located) opposing each other and separated by a gap. End plates 306a and 306b are disposed between the constraint and the cell stack, with each endplate contacting a distal end of the cell stack along the stacking direction, the end plates and the constraint being (e.g., substantially) symmetrically located about the stacking axis, e.g., in a (e.g., substantially) mirror symmetry plane running along the stacking axis of the cells. The contraction and expansion may cause pressure buildup on the battery. Heat may be exerted during the charge and discharge cycles, e.g., in interior 304 of the cell stack. The heat may be dissipated from the battery along arrows 303, e.g., thus increasing the safety of the battery such as by curtailing a runaway reaction. Example 350 shows battery cell 352 rolled upon itself about an axis normal to the drawing page, e.g., in a wound cell (e.g., jelly roll) type configuration. Battery cell 352 is disposed (e.g. located) in battery housing 351. The heat may be dissipated from the battery along arrows 353. The stacked cell arrangement shown in example 300 may have a better thermal conductivity as compared to the rolled battery configuration shown in 350. During a charge and discharge cycle, the battery expands and contracts. The expansion creates a force in the battery in a direction of the stacking direction of the cells and towards the edges of the battery. The contraction and expansion may cause pressure buildup on the battery. One or more constraints may be added to the battery to curb such expansion, e.g., anisotropic constraint configured to deter expansion in the direction perpendicular to arrows 303.

[0106] Fig. 4 shows schematic perspective view examples of energy manipulation devices such as batteries and battery cell architecture therein relative to a Cartesian coordinate system. Example 400 shows a cylindrical battery housing having a length 402 and height 401, which is a diameter. The battery may comprise cell(s) that form a rolled sheet. In example 400, each of the bottom and top faces of the cylinder has a smaller surface area as compared to the side surface of the cylinder - to the curved surface of the cylinder. Example 430 shows a prismatic battery housing that is a rectangular prism, or a cuboid. The battery has length 432, height 431, and width 433. Battery cells 435 are stacked in the battery along height 431, and along the Z direction. In example 430, face XY has a larger surface area than face XZ, and face XY has a larger surface area than face YZ. Example 450 shows a prismatic battery housing that is a rectangular prism, or a cuboid. The battery has length 452, height 451, and width 453. Battery cells 435 are stacked in the battery along length 452, and along the X direction. In example 450, face XY has a larger surface area than face XZ, and face XY has a larger surface area than face YZ.

[0107] In some embodiments, the cell is arranged (e.g., substantially) perpendicular to the face of a prismatic (e.g., cuboid) battery having the largest surface area. At times, the largest surface area face of the anode, the separation space, the separator, the cathode, and / or the dividing space, is disposed (e.g., substantially) normal to the face of the battery having the largest surface area. The anode, the separation space, any separator, and the cathode, may be arranged (e.g., substantially) parallel to each other. The cell components may be configured to arrange about a stacking axis. The stacking axis may be parallel to the face of the housing (e.g., battery housing, enclosure, or casing) having the largest surface area. The stacking axis may be (e.g., substantially) normal to a face type of the electrode having the largest surface area. Fig. 4, 450 shows an example of battery cells, disposed normal to the XY face of the battery, which XY face has the largest surface area among the battery’s faces. The surface area of the cell, in example 450, is at most the surface area of YZ face of the battery, or smaller. Cells arranged normal to the largest surface area face of the battery in which they are disposed (e.g., Fig. 4, 450), have a larger combined cell side (e.g., edge) surface area, as compared to (a) cells arranged parallel to the largest surface area face of the battery in which they are disposed (e.g., Fig. 4, 430) and / or to (b) cylindrical battery such as a wound cell (e.g., jelly roll) battery (e.g., Fig. 4, 400). In some embodiments, the greater the combined side (e.g., edge) surface area of the cells, the greater the residual current role is in the total current of the battery. When the cell comprises at least one uneven side, e.g., as is depicted in Fig. 1, 120, the uneven (e.g., misaligned) side creates a wavy side of a set of cells. The wavy side may or may not contribute to the amount of residual current passing between an anode and a cathode of a cell, e.g., through the insulator.

[0108] In some embodiments, the energy manipulation device such as battery comprises battery cells. The battery cells may be stacked along an axis. A dividing space may be disposed between every two immediately adjacent cells such that a first cell contacts the first face of the dividing space, and a second cell contacts a second face of the dividing space opposing its first space. The dividing space may comprise an insulator, e.g., any insulator disclosed herein. The dividing space may be configured to electrically separate one cell from another. The stack of cells may follow a pattern, the pattern may comprise a sequence. The sequence may comprise an arrangement of components of the battery cell with respect to each other. The sequence may comprise an anode, a separation space, a cathode, and a dividing space. The sequence may follow a CBAS pattern, or a CBASABCS pattern, with “C” designating a cathode, “B” designating a separation space, “A” designating an anode, “S” designating the dividing space, and “E” designates an end plate, e.g., see Fig. 5. The cells may be stacked in one or more groups. The separation space may comprise two opposing faces. A face of the separation space contacting the anode, and an opposing face contacting the cathode. The cell may comprise components comprising an anode, a cathode, a separation space, and an optional dividing space. The dividing space may comprise the same type of material as the separation space. The dividing space and the separation space may be (e.g., substantially) the same. The components of the cell may be disposed along an axis. The components of the cell may be (e.g., substantially) symmetrically arranged along the axis, e.g., in mirror symmetry, the mirror plane running along the axis, and / or in a rotational symmetry, the rotational axis running along the cell stacking axis (e.g., parallel to axis 590 in Fig. 5). At least two components of the cell may extend in a direction (e.g., substantially) perpendicular to the cell stacking axis at a (e.g., substantially) same distance. At least two components of the cell may extend in a direction (e.g., substantially) perpendicular to the cell stacking axis (e.g., laterally) at a different distance from that axis. The different distance extension of the components can form a corrugated (e.g., misaligned) face of the cell, and of the set of cells, e.g., as depicted in Fig. 1, 120. See also sides (e.g., edges) of cell sets in Fig. 5, 500, and 550. In an example, the cathode extends less than the anode, the extension being in a direction perpendicular to the cell stacking axis. In an example, the separation space extends more than the anode and / or more than the cathode, the extension being in a direction perpendicular to the cell stacking axis.

[0109] Fig. 5 shows a schematic cross-sectional example 500 of a battery comprising cathode 502, anode 505, separation space 506, and dividing space 507. The battery cells are disposed in volume 504 of the battery that can include an insulator. The battery cells are stacked along an axis 590, in a repeating CBAS arrangement. Each anode “A” in the battery is operatively coupled (e.g., connected) with a current collector such as 513, the anode current collectors being coupled in parallel to a main anode current collector 514, endingwith cathode contact 511. Each cathode “C” in the battery is operatively coupled (e.g., connected) with a current collector such as 516, the anode current collectors being coupled in parallel to a main cathode current collector 517, ending with anode contact 512.

[0110] Fig. 5 shows a schematic cross-sectional example 550 of a battery comprising cathode 552, anode 555, separation space 556, and dividing space 557. The battery cells are disposed in volume 554 of the battery that can include an insulator. The battery cells are stacked along an axis 590, in a repeating CBASABCS arrangement. Each anode “A” in the battery is operatively coupled (e.g., connected) with a current collector such as 563, the anode current collectors being coupled in parallel to a main anode current collector 564, ending with cathode contact 561. Each cathode “C” in the battery is operatively coupled (e.g., connected) with a current collector such as 566, the anode current collectors being coupled in parallel to a main cathode current collector 567, ending with anode contact 562. In Fig. 5, the main cathode current collector is disposed at a different face of the set of cells as the main anode current collector, which is the opposing face.

[0111] In some embodiments, the battery comprises one or more main current collectors, e.g., as disclosed herein. The main current collector may include a busbar and / or a busbar extender. The main current collectors may or may not contact the insulator covering the edges of the cells. In the example shown in Fig. 5, 500, the main current collectors 517 and 514, are separated from the insulator 504 by a gap. In the example shown in 500, the main current collectors 517 and 514 contact the insulator 504.

[0112] In some embodiments, an end plate is disposed at a distal end of a cell set, e.g., at opposing distal ends of the set of cells and along the cell’s stacking axis (e.g., Fig. 5, 590). Fig. 5, 500 shows an example of two opposing end plates disposed at both distal ends of a set of stacked cells, the end plates designed by “E,” the end plate 520 contacting the insulator at its opposing lateral ends. Fig. 5, 550 shows an example of two opposing end plates disposed at both distal ends of a set of stacked cells, the end plates designed by “E,” the end plate is devoid of the insulator at its two opposing lateral ends - normal to stacking axis 590.

[0113] In some embodiments, an energy storage device such as a battery, comprises a plurality of cells. Each of the cells comprises an anode separated by a gap from a cathode. The gap may comprise a separator. The cell may comprise one or more electrolyte types. Each of the electrodes (e.g., anode and cathode) comprises a current collector, e.g., a strip, a foil, or a film, of conductive material on which the active electrode material is disposed of. The conductive material may comprise an elemental metal, a metal alloy, or an allotrope of elemental metal. In an example, the elemental metal comprises aluminum or copper. In an example, the metal alloy may comprise stainless steel. In an example, the allotrope of elemental metal may comprise carbon nanotubes, or carbon fibers. The tubular structures(e.g., nanotubes) may comprise nestled tubes, e.g., at least about 2, 3, 4, or more nestled tubes. The carbon fibers may be weaved, randomly dispersed, or any combination thereof. The strip of conductive material may or may not comprise a composite material. At least two cells in the energy storage device (e.g., battery) may be stacked in a direction (e.g., substantially) normal to their face having the largest surface area. The electrode has an electrode face having the largest surface area, and the counter-electrode has a counterelectrode face having the largest surface area. In some embodiments, there is a difference in a volume of the cell between a state of charge and a state of discharge of an electrode of the cell. The volume of the cell may repeatedly and / or reversibly alter between the state of charge and the state of discharge repeatedly. The reversible discharge may not be completely reversible, e.g., there may be an attrition in the properties of one or more components of the cell during a cycle of charge / discharge. The repeated cycling between the state of charge / discharge may comprise at least about 150 cycles, 200 cycles, 250 cycles, 300 cycles, 400 cycles, 500 cycles, 700 cycles, 800 cycles, 1000 cycles, 1200 cycles, or 1500 cycles. The repeated cycling between the state of charge / discharge may comprise any value of cycle between the aforementioned cycles, e.g., from about 150 cycles to about 1500 cycles. In some embodiments, there is a difference in a volume of the cell between a state of charge and a state of discharge of an electrode of the cell. The change in volume may comprise a change in at most about 20*, 25*, 50*, 100*, 200*, 300*, or 400* of an initial volume of the cell. The change in volume may comprise a change in at least about 10*, 25*, 50*, 100*, 200*, or 300* of an initial volume of the cell. The change in volume may comprise a change in any of the forementioned values, e.g., from about 10* to about 400*, from about 100* to about 400*, or from about 20* to about 200*. The symbol “*” designates the mathematic operation of multiplication.

[0114] The energy storage device may comprise at least one constraint (e.g., a brace, or a harness). The constraint may be configured to (e.g., substantially) maintain constant dimensions and / or volume of the energy manipulation device during the charge / discharge operations. The constraint may be configured to maintain internal pressure in the energy manipulation device, e.g., during the charge / discharge operations. The internal overpressure in the energy manipulation device may be at most about 100PSI, 150PSI, 200PSI, 500PSI, 1000 PSI, 2000 PSI, 3000 PSI, 5000PSI, or 10000PSI. The internal overpressure in the energy manipulation device may be at most about 50 PSI, 100PSI, 150PSI, 200PSI, 500PSI, 1000 PSI, 2000 PSI, 3000 PSI, or 5000PSI. The internal overpressure in the energy manipulation device may be between the above referenced pressures, e.g., from about 50PSI to about 10000 PSI, from about 50PSI to about 500PSI, or from about 50PSI to about 2000PSI, or from about 100PSI to about 3000PSI. The internal overpressure in the energy manipulation device may be greater than the ambient pressure external to the energymanipulation device, e.g., above 14.6 PSI. In some embodiments, the energy storage device has a face type having the largest surface area among its face types. The face a face type having the largest surface area may deform (e.g., bend) during the, or as a consequence of, the overpressure phase. The face type having the largest surface area may (e.g., substantially) reversibly deform during the life of the energy manipulation device. Substantial reversal of the face’s deformation may be within the specification and / or intended use of the energy manipulation device.

[0115] In some embodiments, the battery cell set is disposed in an orthogonal stacked configuration.

[0116] In some embodiments, the energy manipulation device comprises a constraint system. The constraint system may be applied over one or both of the X-Y surfaces of the energy manipulation device (e.g., battery). In some embodiments, the constraint system includes a plurality of perforations to facilitate distribution (e.g., by flow of) an electrolyte solution after the cell, or cell set, has been assembled. In some embodiments, the casing comprises stainless steel, aluminum, titanium, beryllium, beryllium copper (hard), copper (O2 free, and / or hard), nickel, other metals or metal alloys, composite, polymer, ceramic, any plurality thereof, any combination thereof, or any other suitable material as applicable.

[0117] Fig. 6 shows in example 600 an exploded view of a pair of constraints 601a and 601b encasing a set (e.g., a population) of stacked battery cells 602, the pair of constraints being part of a constraint system. Example 650 shows an exploded view in which the two constraints 601 a-b are closer to the stacked cell set 602. Fig. 6 is shown with respect to a Cartesian coordinate system. Each of the constraints may curb expansion of the battery cells during charge and / or discharge. Curbing the expansion may or may not be anisotropic. In the example shown in Fig. 6, the constraint can deter expansion of the cells anisotropically along the Y axis.

[0118] In some embodiments, the cell comprises an anode separated by a gap from an anode. The cell may comprise a separator disposed in the gap. The cells may be elongated, e.g., an elongated box. The face of the cell opposing the largest surface area face of the electrode (e.g., anode or cathode) may have an aspect ratio of at least about 10:1 , 15:1, 20:1 , 35:1, or 50:1, the aspect ratio being a length (e.g., Fig. 7, 731) of the face to a height (e.g., Fig. 7, 732) of that face. The cell may have an aspect ratio between the aforementioned values, e.g., from about 10:1 to about 50:1, the aspect ratio being the length of the cell to the height. The cell may have an aspect ratio of at least about 1:1 2: 1 , 4: 1 , 5:1, 8:1 , 10:1, 15:1, 20:1, 25:1, 30:1, 35:1, 50:1 , or 100:1, the aspect ratio being a height (e.g., Fig. 7, 732) of the cell to a width (e.g., Fig. 7, 704, showing a width of three cells). The cell may have an aspect ratio between the aforementioned values, e.g., from about 5:1 to about 50:1 , the aspect ratio being the height of the cell to the width.

[0119] Fig. 7 shows in example 700 a lateral portion of three cells, each comprising an electrode such as 701, a counter electrode such as 703, and a separator 702 disposed between each immediately adjacent pair of electrode and counter electrode. In example 700, the electrode (e.g., 701) extends less than the counter electrode 703 to the lateral edge 704 of the stacked cells, with the separator extending more towards the edge than the electrode, and then the counter-electrode, e.g., thus forming a corrugated, or wavey, lateral edge 704. Example 730 shows a stack of cells, e.g., in which the cells are horizontally stacked. The stacking axis of the cells may be parallel to a face of the cell having the largest surface area, e.g., of a prismatic battery.

[0120] Example 750 shows a set of stacked cells 751 enclosed by two opposing casings 752a and 752b. Current collectors of the stacked cells are coupled with connectors 753a and 753b. 753a connect to the electrodes of the set of cells, and 753b connects to the counterelectrodes of the set of cells. The cells enclosed by the casings (e.g., housing or case), are further secured by a flexible material 755, e.g., a band. The flexible material may comprise a polymer or a resin. The flexible material may be an electrical insulator. The casing may comprise one or more openings. In the example of Fig. 7, casing 752a includes oblong openings, e.g., that are evenly spaced along the X direction. Fig. 7 is shown with respect to a Cartesian coordinate system.

[0121] Fig. 8 shows in example 800 an exploded view of a pair of constraints 801a and 801b of a constraint system encasing a set (e.g., a population) of stacked battery cells 802. Each of constraints 801 a-b includes oblong openings, e.g., that are evenly spaced along the X direction. Fig. 8 is shown with respect to a Cartesian coordinate system. The constraint may form a cage, e.g., having one or more openings such as slits, e.g., oblong silts or holes.

[0122] In some embodiments, the cell is configured with at least one gap portion that can be occupied during expansion of the active material. The gap may be between the electrode and counter electrode, or adjacent to an edge (e.g., side) of the electrode. Some of the cells described herein comprise gaps located adjacent to the electrode(s), e.g., at side(s) of the electrode(s). These gaps may enable electrolyte to flow into the gaps, e.g., during buffering.

[0123] Example 830b is a microscope image of section 830a. The image shows a set of cells comprising (a) anodes including (i) anode active material such as 831 and (ii) anode current collector such as anode current collector 832; (b) anodes including (iii) anode active material such as 833 and (iv) cathode current collector such as cathode current collector 834; (c) separators such as separators 835 and 836; and (d) insulating material such as 837. The insulating material 837 is disposed in a side gap at the edge of the electrode. Each cathode is separated from its immediately adjacent anode by a gap, the separator disposed in the gap. In the example shown in 830, a pair of immediately adjacent separators are separated from each other. The separators extend more toward an edge of the set of cells,as compared to the cathode, which extends more towards the edge than the anode. The insulator is disposed in the volume between the set of cells and the edge of the set of cells. The ends of the separators along the z direction alternate between a first pair of immediately adjacent separator ends pointing towards each other, and a second pair of immediately adjacent separator ends pointing away from each other, the ends being along the z direction. For example, the ends of separators 835 and 836 point towards each other. Each anode and cathode in the cell interlace each other along the y direction (e.g., are disposed alternatively), which is the stacking direction of the cells. In the example shown in 830b, (a) the active anode material is disposed at both sides of the respective anode current collector and (b) the active cathode material is, disposed at both sides of the respective cathode current collector, the sides being along the z direction. In the example shown in 830b, (a) the active anode material is disposed on both side of the anode current collector such that it (e.g., substantially, schematically and / or generally) forms a mirroring plane for the anode active material, and (b) the active cathode material is disposed on both side of the cathode current collector such that it (e.g., substantially, schematically and / or generally) forms a mirroring plane for the anode active material.

[0124] Example 860b is a microscope image of section 860a. The image shows a set of cells comprising (a) anodes including (i) anode active material such as 861 and (ii) anode current collector such as anode current collector 862; (b) anodes including (iii) anode active material such as 863 and (iv) cathode current collector such as cathode current collector 864; (c) separators such as separator 865. Each cathode is separated from its immediately adjacent anode by a gap, the separator disposed in the gap. In the example shown in 860, the cathode active material extends to the edge of the cell in the X direction, and bends towards the Y direction to electrically connect its immediately adjacent cathode current collector along the Y direction. The bend portions (e.g., tabs) of the cathode current collectors are joined by a material operatively (e.g., electrically) coupling the tabs, including a tacky connector 867, to form a busbar. In the example shown in Fig. 8, the cathode contacts the separator that contacts the anode, which contacts any additional separator in the set of cells. Endplates may be disposed at both end of the set of cells along the stacking direction, e.g., along the Y direction.

[0125] In some embodiments, the interior of the casing is separated from an exterior of the casing, e.g., to hinder reactive specie(s) in the external environment to traverse to the interior environment such as to cause the harm. Terminals configured to conduct the electrical current flow are configured to allow electrical connectivity of the external environment with the cell(s) disposed in the interior of the housing. The housing comprises a seal to separate the interior environment of the housing from its exterior environment. The terminals extend through the seal from the interior of the housing to the externalenvironment. Each of the terminals can be coupled with the housing (e.g., at the seal area) by coupler. The coupler may comprise a compressible material such as a malleable material. The terminal may be secured to the housing by an adhesive, e.g., at the seal. The terminal may be secured to the seal at least in part by the adhesive and / or by the compressible material. The compressible material may be an adhesive. The compressible material and / or the adhesive, may comprise a polymer, a resin, a combination thereof, or a plurality of types thereof. The adhesive may be (e.g., substantially) confined to the seal. The adhesive may comprise polypropylene or epoxy glue. The fuse may be reinforced by an adhesive, e.g., to any portion of the energy manipulation device such as disclosed herein. The fuse may be located (e.g., and reinforced to) a portion of the energy manipulation device sufficiently distant from susceptible material(s) such that when the fuse activates, the harm will not be made due to activation of the susceptible material(s). The susceptible material may participate in the chemistry of the energy manipulation device, e.g., of the cell. The susceptible material(s) may comprise any of the active materials of the cell, any electrolyte, any separator, any insulator, any divider, any current collector, any busbar, any adhesive, any plurality (e.g., of types or otherwise) thereof, or any combination thereof. The compressible material may be disposed in the seal, in an interior of the housing, in the exterior of the housing, or any combination thereof. In some embodiments, the terminal is compressed by the compressible material, which is compressed by the seal of the housing.

[0126] In some examples, the battery is disposed in a housing comprising a pouch. The pouch may insulate the battery content (e.g., the cell therein) from one or more reactive agent in the ambient environment external to the pouch. The pouch may enclosure the case of the battery, and the cell(s) housed therein. The pouch may comprise one or more layers. The one or more layers may include a material comprising a polymer, a resin, an elemental metal (e.g., strip, film, foil, and / or powder thereof), or a metal alloy (e.g., strip, film, foil, and / or powder thereof). The one or more layers may include one or more of these materials. The pouch may have an external surface having a color comprising black, silver, or white.

[0127] In some embodiments, the cell(s) are enclosed in a rigid enclosure surrounding the cell(s). The rigid enclosure may comprise the constraint system and / or endplates. The enclosure may comprise elemental metal, metal alloy, an allotrope of elemental carbon, a polymer, a resin, a plurality of types thereof, or any combination thereof. The housing may be of a material of (e.g., substantially) the same hardness, or a lesser hardness (e.g., softer), or of a higher hardness, as compared to the enclosure. In an example, the housing may comprise a pouch having a lesser hardness than the enclosure. The pouch may be nested in a harder housing (e.g., a can), as compared to the enclosure and / or as compared to the pouch. The enclosure may be protected by a layer that cushions an interaction between the enclosure and the softer housing. The protection layer may comprise an elastic material, apolymer, a resin, any plurality thereof, or any combination thereof. The protection layer may be in the form of a band surrounding sides of the enclosure. The sides may be of side types having smaller surface area. The sides may be other than side types having the largest surface area. The protection layer may have a thickness, elasticity, and / or durability that enable cushioning of an interaction between the enclosure and the softer housing immediately adjacent thereto. The protection layer may assume a shape of a sponge. The protection layer may or may not be porous. The protection layer may include polyurethane, polypropylene, polyethylene, and / or rubber. The protection layer may be attached to the enclosure by adhesion and / or by being compressed thereto, e.g., similar to a band’s compression.

[0128] In some embodiments, charge carriers (e.g., Li ions) reside in a cathode when the battery is in a discharged state, and reside in the anode when the battery is in a charged state. For example, when a battery charges, charge carriers (e.g., carrier ions) migrate into one or more electrode active materials. As the charge carriers traverse (e.g., move) in and out of the active material of the electrodes, the active material undergoes a volume change. The movement in an out of the active material may be referred to as ingress and egress of the charge carriers relative to the active material. The amount of expansion may differ depending on the active materials used for the electrode. For example, a graphite electrode may expand by about 6% to 10% when the graphite electrode is charged. In another example, a silicon electrode may expand up to 300% when the silicon electrode is charged. In another example, a silicon oxide electrode may expand up to 210% when the silicon oxide electrode is charged. In another example, an electrode comprising silicon may expand up to about 20%, 50%, 75%, 100%, 200%, 300%, or 350% when the silicon electrode is charged, the percentage being volume per volume.

[0129] In some embodiments, an energy storage device such as a battery, comprises a plurality of cells. Each of the cells comprises an anode separated by a gap from a cathode. The gap may comprise a separator. The cell may comprise one or more electrolyte types. Each of the electrodes (e.g., anode and cathode) comprises a current collector, e.g., a strip, a foil, or a film, of conductive material on which the active electrode material is disposed of. The conductive material may comprise an elemental metal, a metal alloy, or an allotrope of elemental metal. In an example, the elemental metal comprises aluminum or copper. In an example, the metal alloy may comprise stainless steel. In an example, the allotrope of elemental metal may comprise carbon nanotubes, or carbon fibers. The tubular structures (e.g., nanotubes) may comprise nestled tubes, e.g., at least about 2, 3, 4, or more nestled tubes. The carbon fibers may be weaved, randomly dispersed, or any combination thereof. The strip of conductive material may or may not comprise a composite material. At least two cells in the energy storage device (e.g., battery) may be stacked in a direction (e.g.,substantially) normal to their face having the largest surface area. The electrode has an electrode face having the largest surface area, and the counter-electrode has a counterelectrode face having the largest surface area. In some embodiments, there is a difference in a volume of the cell between a state of charge and a state of discharge of an electrode of the cell. The volume of the cell may repeatedly and / or reversibly alter between the state of charge and the state of discharge repeatedly. The reversible discharge may not be completely reversible, e.g., there may be an attrition in the properties of one or more components of the cell during a cycle of charge / discharge. The repeated cycling between the state of charge / discharge may comprise at least about 200 cycles, 500 cycles, 800 cycles, 1000 cycles, 1200 cycles, or 1500 cycles. In some embodiments, there is a difference in a volume of the cell between a state of charge and a state of discharge of an electrode of the cell. The change in volume may comprise a change in at most about 20%, 25%, 50%, 100%, 200%, 300%, or 400% of an initial volume of the cell. The change in volume may comprise a change in at least about 10%, 25%, 50%, 100%, 200%, or 300% of an initial volume of the cell. The change in volume may comprise a change in any of the forementioned values, e.g., from about 10% to about 400%, from about 100% to about 400%, or from about 20% to about 200%. The charge carriers may interact with the active material (e.g., comprising silicon) such as in an intercalation and / or alloying process (e.g., Li- Si alloying). The Li-Si alloying may form alloys comprising LiisSi4 or Li22Sis. The lithium alloying of silicon may allow silicon to store at least 5*, 10*, or 15* more lithium as compared to graphite, with the operation “*” designating the mathematical operation of “times.”

[0130] In some embodiments, the energy manipulation device has prescribed conditions and / or a prescribed lifetime. Operation of the energy manipulation device (e.g., battery) may be during its prescribed lifetime, during its prescribed use, and / or according to jurisdictional standards relating to the energy manipulation device. The prescribed lifetime may depend on the number of charge and discharge cycles, e.g., as disclosed herein. The number of cycles may be to full charge before the capacity of the energy manipulation device (e.g., battery) drops below 80%. The prescribed lifetime may be of at most about 3 years, 5 years, 6 years, or 7 years, e.g., from the date of its manufacture. The energy manipulation device may have a shelf life of at least about 6 months, or 12months. The standards may include, SAE J2380, MIL-STD-810G (516.6), UL (e.g., UL1642 and / or UL 2054), SAE J2380, GB31241, MSDS, UL (UL1642), CE, CB, UN (e.g., UN38.3), RoHS, REACH, IEC (e.g., IEC 60068-2-6, IEC 60068-2, and / or IEC62133), DOT, IATA, GB, CTIA, PSE, or any combination thereof. The prescribed operating conditions comprise temperatures between a lower temperature (e.g., - 20°C) and a higher temperature (e.g., 80°C). The higher temperature may be of at most about 60°C, 70°C, 80°C, 85°C, or 90°C. The higher temperature may be of at least about 40°C, 50°C, 55°C, 60°C, 70°C, or 80°C. The lower temperature may be of at most about -10°C, -20°C, -30°C, -40°C, or -60°C,. The lower temperature may be of at least about -20°C, -10°C, or 0°C. The temperature may be between any of the aforementioned values, e.g., from about 60°C to about -20°C, or from about 90°C to about -40°C. The energy manipulation device may retain at least about 70%, 80%, or 85% of its capacity the lower temperature as compared to its capacity at ambient temperatures, e.g., at room temperature such as 20°C or 25°C.

[0131] In some embodiments, the energy manipulation device is rechargeable. The energy manipulation device may be configured to allow fast charging (e.g., allowing the cell(s) to fully charge in five minutes). The energy manipulation device may have a C-rate of at least about 0.2C, 0.5C, 1 C, 2C, 3C, 5C, 7C, 10C, 12C, or 15C, 30C, or 40C. The C-rate may be charging the energy manipulation device to 80% capacity, or to 90% capacity. The energy manipulation device may have a C-rate of any value between the aforementioned values, e.g., from about 0.2C to about 40C, from about 02C to about 5C, from about 3C to about 30C, from about 10C to about 40C or from about 2C to about 7C. The energy manipulation device may be charged to at most about 30sec, 3 min. 6min. 10min, 12min, 15 min, 30min, the charging being to 80% or to 90% capacity. The energy manipulation device may allow to choose the mode of discharge and / or of charge. The discharge and / or of charge, may be in a continuous mode, in a pulsed mode, or in a combination of a continuous mode and pulsed mode. In some embodiments, the battery has a N / P ratio greater than one. The N / P ratio may be at least about 1.05, 1.1, or 1.15. The cell configuration, cell set architecture, and / or chemical makeup (e.g., of the electrode active material(s)), may allow for buffering such as pre-lithiation. The cell, cell set, and / or battery disclosed herein, may facilitate maintenance of cyclable charge carriers (e.g., lithium) in the anode, e.g., also at beginning of charge (BOC). The cell, cell set, and / or battery disclosed herein may provide for better conductivity and / or for lower overpotential in anode deposited material (e.g., cake comprising the active material). The cell, cell set, and / or battery disclosed herein may provide for reduced (a) cycling window and / or (b) damage due at least in part to expansion and contraction during the charge and discharged states of the cell. The cell, cell set, and / or battery disclosed herein may provide for high voltage at BOC, e.g., without buffering, e.g., without pre-loading of the charge carrier into the active material of the electrode such as in a pre-lithiation process. The nominal voltage of the energy manipulation device may be at least about 3.6 Volts (V), 3.7V, 3.8V. The working voltage of the energy manipulation device may be at least about 3V, 3.7V, 3.8V, 4.0V, 4.2V, 4.35V, 4.5V, 4.75V, 4.9V, or 5.0V. The working voltage of the energy manipulation device may be between any of the aforementioned values, e.g., from about 3V to about 5V, from about 3V to about 4V, or from about 4V to about 5V. The weight of the energy manipulation device may be at most about 1 gram(gr), 1.5gr, 1.8gr, 2gr, 3.5gr., 6gr, 46gr, 47gr, 50gr, 69gr, 70gr, 71 gr., or 100gr. The weight of the energymanipulation device may be at any value between the aforementioned values, e.g., from about 1.8gr to about 100 gr. The volumetric density of the energy manipulation device may be at least about 800 Watt hour per liter (Wh / liter), 805 Wh / liter, 820 Wh / liter, 900 Wh / liter, 1300 Wh / liter, or 1500 Wh / liter. The gravimetric density of the energy manipulation device may be of any value between the aforementioned values, e.g., from about 800 Wh / liter to about 1500 Wh / liter. The volumetric density of the energy manipulation device may be at least about 300 Watt hours per kilogram (Wh / Kg), 320 Wh / Kg, 350 Wh / Kg, 395 Wh / Kg, 400 Wh / Kg, 500Wh / Kg, 1000 Wh / Kg, 2000 Wh / Kg or 3000 Wh / Kg. The gravimetric density of the energy manipulation device may be of any value between the aforementioned values, e.g., from about 300 Wh / Kg to about 3000 Wh / Kg, from about 300 Wh / Kg to about 400 Wh / Kg, or from about 400 to about 3000 Wh / Kg. The electrical charge capacity of the cell may be of at least about 200 milliampere hours (mAmph), 240 mAmph, 280 mAmph, 600 mAmph, 1 Amper hour (Amph), 30 Amph, 50 Amph, or 70 Amph. The electrical charge capacity of the cell may be between any of the aforementioned values, e.g., from about 200 mAmph to about 800 mAmph, from about 200 mAmph to about 1 Amph, from about 1 Amph to about 30 Amph, or from about 30 Amph to about 80 Amph.

[0132] In some embodiments, the anode comprising silicon is thinner than an anode comprising graphite, e.g., has a smaller height such as shown in Fig. 2, 205. The anode height may be at most about 30%, 35%, 40%, 50%, 65%, 75%, or 80%, height (i.e. , thickness) of a graphite anode for a for a given loading of anode active material. The anode height may be at least about 10%, 20%, 30%, 35%, 40%, 50%, 65%, or 70%, height (i.e., thickness) of a graphite anode for a for a given loading of anode active material. As compared to a graphite anode for a for a given loading of anode active material, the anode height may be between any of the aforementioned percentages, e.g., from about 10%, to about 70%, or from about 30% to about 70%. In an example, the height difference in graphite anode vs. silicon anode when discharged is 35%. In an example, the height difference in graphite anode vs. silicon anode is anode is 65% of the size of the graphite anode for a given loading, when each of the anodes is fully formed. A thinner anode may allow for better current distribution through the electrode and / or lower likelihood of charge carrier plating (e.g., reduction to its elemental state) such as lithium plating.

[0133] In some embodiments, the cell comprises an anode separated by a gap from an anode. The cell may comprise a separator disposed in the gap. The cells may be elongated, e.g., may assume a shape of an elongated box. The face of the cell opposing the largest surface area face of the electrode (e.g., anode or cathode) may have an aspect ratio of at least about 10:1, 15:1, 20:1 , 35:1, or 50:1 , the aspect ratio being a length (e.g., Fig. 4, 431) of the face to a height (e.g., Fig. 4, 432) of that face. The cell may have an aspect ratio of atleast about 5:1 , 8:1, 10:1, 15:1, 25:1 20:1, 35:1, or 50:1 , the aspect ratio being a height (e.g., Fig. 4, 432) of the cell to a width.

[0134] Fig. 9 depicts an illustrative example of a battery having a busbar extension, in accordance with some embodiments of this disclosure. Example 900 shows a battery having a busbar extension member connecting a busbar to a proximal tab. Example 900 comprises busbar extension member 901 (as an example of an interconnect component of the battery), population of negative electrodes electrically connected schematically at 921, population of positive electrodes connected schematically at 922, population of electrically insulating separator layers 943, terminal tab 941, terminal tab 942, housing 972 having top portion 972A. In some implementations, housing (e.g., battery enclosure) 972 is filled with nonaqueous electrolyte (not shown) and lid 972A may be folded over and sealed to an upper surface of battery housing 972 in order to enclose the negative and positive electrodes. To permit connection to an energy supply or consumer (not shown), terminal tabs 941 and 942 extend out of the sealed enclosure. The direction of the tabs may be parallel to, or perpendicular to, the direction of the stacking of the individual electrodes in the internal electrode stack and parallel to the direction of the progression of the series of interdigitated electrodes in each electrode structure in the internal electrode stack. The arrangement of cells within the housing can be any one of the arrangements shown in Fig 3-8, including a jelly roll type cell arrangement.

[0135] In some embodiments, extension member extends an electrode (e.g., anode or cathode) from the outlet of a cell, around a side of the cell, and to a coupler such as a grommet. As shown in 9, example 930 depicts an edge portions of an energy storage device, e.g., a battery. The energy manipulation device comprises cells including alternating structure of electrodes and counter electrodes separated from each other by a gap such as 932, e.g., comprising a separator. Each electrode type (e.g., each anode and each cathode) includes its respective current collector onto which active material is deposited (e.g., at one or at both sides). The current collector of each anode type extends laterally by an extended portion - by a tab such as tab 933. The tab of current collectors of an electrode type, extends to the same lateral direction beyond an edge of the separator, the separator extending laterally beyond each of the electrode types. In some embodiments, the tabs extending from each anode (e.g., tab 933) are folded relative to the rest of the current collector, e.g., in at least one direction along a stacking axis of the cells. In some implementations, busbar 935 is connected to the tabs extending from each anode (e.g., tab 933), for clarity purposes the tabs are not shown folded in the example of 930. In some embodiments, terminal tabs extend from the battery (e.g., tabs 941 and 942). The set of cells may be encased in a constraint system formed by two opposing constraints 937a and 937b, and by two opposing end plates such as end plate 938. In some embodiments, example 930comprises busbar 935. In some implementations, a busbar extender extends from busbar 935 and connects to terminal tabs, e.g., busbar extension member 901.

[0136] In some embodiments, various cell components are fabricated using the rotary dicer. The rotary dicer may cut strips from which cell components are fabricated, e.g., electrodes and / or separator. The strips may comprise aligners and optional busbar engagers, sized and shaped to allow a busbar pass through the tabs in order to mechanically reinforce the structure of the battery assembly and to electrically couple the tabs across the battery assembly. In some embodiments, the active material layer may comprise cathodically and anodically active materials disclosed herein, such as Lithium-Transition Metal Oxides and / or Silicon containing compounds. In some embodiments, the current collectors may comprise elemental metals, or any other material suitable for current collectors (e.g., aluminum or copper). Techniques suitable to form apertures (e.g., busbar engager and aligners) may be employed to form the aperture in the size and shape necessary to allow a busbar to be passed through. For example, laser processing, cutting such as by the rotary dicing, pressing, stamping, forging, and / or otherwise mechanically cutting. The laser processing may include dicing and / or ablating. The laser processing may be slower than the mechanical cutting by the rotary dicer. The laser processing may cause debris to accumulate onto the cut product, e.g., due to expelled liquid material due to the laser operation (e.g., ablating and / or dicing). Operation of a rotary dicer may be quicker and / or cleaner, as compared to laser processing to generate the cut and / or embossed parts. Laser processing may cause debris including dross, soot, and / or other debris. The debris may fall, cling, melt and solidify onto, or otherwise attach, to the requested product. Operation of the laser may be limited to certain aspects of the requested product, e.g., small design cutting / embossing, sharp angles, or any combination thereof. The rotary dicer may be configured to generate the product that lessens the extent of (e.g., is devoid of) the debris types caused by the laser processing.

[0137] Fig. 10 depicts various strip examples from which electrodes for cells are to be fabricated, e.g., using the rotary dicer. The strip examples of Fig. 10 are viewed horizontally, e.g., from the top and / or bottom of the strip. In some embodiments, the trip may be symmetrical along the plane of the strip, e.g., by mirror symmetry. In some embodiments, the trip may be symmetrical along a long axis of the strip, e.g., by rotational C2 symmetry. The strips may be cutout sections generated by the rotary dicer. The various strips have different tab section configurations. The strip may be a current collector strip covered by active material from one or both of its sides. The strip may be a separator strip.

[0138] Example 1000 shows a strip including active material section 1003, tab sections 1004a and 1004b at two distal sides of active material section 1003, each of tab sectionbeing rectangular. The strip includes alignment features 1001a and 1001b, and optional busbar engagers (D-slots) 1002a and 1002b.

[0139] Example 1020 shows a strip including active material section 1023, tab sections 1024a and 1024b at two distal sides of active material section 1023, each of tab section being in the form of the capital letter “T” with its top section contacting the narrow side of active material section 1023, each of opposing sides of the tab comprising a curvature, the opposing sides of the tabs being related by mirror symmetry along a plane perpendicular to strip 1020, and running along the long axis of strip 1020. The strip includes alignment features 1021a and 1021b, and optional busbar engagers (D-slots) 1022a and 1022b.

[0140] Example 1040 shows a strip including active material section 1043, tab sections 1044a and 1044b at two distal sides of active material section 1043, each of tab section being in the general form of the capital letter “T” with its top section contacting the narrow side of active material section 1043, each of opposing sides of the tab comprising a curvature, the opposing sides of the tabs being related by mirror symmetry along a plane perpendicular to strip 1040, and running along the long axis of strip 1040. The strip includes alignment features 1041a and 1041b, and optional busbar engagers (D-slots) 1042a and 1042b.

[0141] Example 1080 shows a strip including active material section 1083, tab sections 1084a and 1084b at two distal sides of active material section 1083, each of tab section including a symmetrical trapezoid with its base section pointing towards the narrow side of active material section 1083, the opposing sides of the tabs being linear (non-curved) and are related by mirror symmetry along a plane perpendicular to strip 1080, and running along the long axis of strip 1080. The strip includes alignment features 1081a and 1081b, and optional busbar engagers (D-slots) 1082a and 1082b.

[0142] In some embodiments, the tabs are coupled to the busbar, e.g., by a coupler comprising one or more adhesive strips. Fig. 11 shows an example of a portion of a cell stack including cell 1103, which is held by constrain system 1101a and 1101b separated from each other by a gap. Distal endplate 1104 is engaged with the constraint system, and contacts the cell stack. Busbar 1108 contacts a tab at the distal side of each electrode. In the example shown in Fig. 11 , busbar 1108 contacts the cell stack tabs (e.g., also) by adhesive strips 1120A and 1120B.

[0143] In some embodiments, the rotary dicer is part of a multi-step fabrication process, e.g., manufacturing process. The rotary dicer may enable a roll-to-roll fabrication process. The multi-step fabrication process may comprise embedding, coating, printing, laminating, calendering, pressing, laser processing, pressing, other mechanical cutting, stamping, or any combination thereof. The rotary dicer may be part of a roll-to-roll fabrication process, or any other multi-step fabrication process. The multi-step fabrication processes may include roll-to-roll, cutting, forming, machining, welding, punching, casing, depositing, drying, spraying, 3D printing, calendering, compressing, ablating, dicing, adhering (e.g., gluing), soldering, any plurality of types thereof, or any combination thereof. In an example, a sheet of current collector material may be coated with its respective active material (e.g., as a slurry), which is subsequently dried, compressed, and calendered. The slurry may comprise a formulation providing adhesive properties such that the active material (e.g., particulate material) adheres to itself, and adheres with the current collector. Such may be configured to withstand the manufacturing process, e.g., by the rotary dicer. The processed sheet may then be subject to cutting using the rotary dicer to generate cuttings, e.g., strips such as in Fig. 10. These strips can ultimately form the electrode of the energy manipulation device. The cuttings may include alignment holes, e.g., cuttings alignment holes. The cuttings may include engagement holes, e.g., to engage the cutting with a busbar. The cuttings may comprise an electrode, a counter-electrode, or a separator. The cuttings’ alignment holes (e.g., Fig. 10, 1001a and 1001b) may be configured to align the cuttings upon stacking along a stacking axis, e.g., to form the cell stack. The electrode portions cut at least in part by the rotary dicer, may be stacked along posts (e.g., rods and / or columns), e.g., when the alignment structures engage with the posts at the two distal sides of the current collector (e.g., Fig. 17, 1701a and 1701b). The cuttings’ engagement holes (e.g., Fig. 10, 1002a and 1002b) may be configured to engage the cuttings with their respective busbar, e.g., to form an electrical connection. Upon fabrication of the cell stack (e.g., and optional engagement with the busbar), the distal section of the cuttings that includes the cutting’s alignment holes are cut. The resulting cell stack may or may not comprise the strip section having the engagement holes. The resulting cell stack may be encased with distal end plates, with the constraint system, and / or with a housing, e.g., a pouch or rigid housing such as a casing. As such, the rotary dicer may be part of a manufacturing process of the energy manipulation device, e.g., battery. The cell stacked may be subsequently subject to buffering before being designated for (e.g., commercial) use. One or more operations of the fabrication process may be manually controlled. One or more operations of the fabrication process may be automatically controlled, e.g., using a control system such as disclosed herein. The calendering may comprise temperature conditioning, e.g., heating. The operation of the rotary dicer may comprise temperature conditioning, e.g., as disclosed herein. One or more manufacturing conditions may require temperature conditioning, e.g., using any of the temperature conditioning systems disclosed herein, as applicable. The control system may be configured to automatically control the temperature during the temperature conditioning. The temperature conditioning may be manually and / or automatically controlled, e.g., using a control system such as disclosed herein.

[0144] In some embodiments, at least a portion of a cell component is (e.g., further processed) processed via a press system configured to execute a punching action. The punching action can require a male- female type engagement that shears a target starting material disposed between the male and female members of the press system. The target starting material to be cut, may adhere to and / or pushed with, a male member into a female member with which the male member engages with. In some embodiments, the punched resulting piece (e.g., product) is generated by shearing. The more edges are in the design to be cut by the press system (e.g., design to be punched), the larger the shear force required for the punch, thus the more violent the punch will be. Such violent action of the press system may cause harm (e.g., deformation) to target starting material, e.g., to any particulate material deposited on structure that constitutes the target starting material. In an example, the particulate material comprises an active material deposited on a current collector, which together constitute the target starting material. In an example, the particulate material is a ceramic coupled with a polymer that together constitute the which together constitute the target starting material for the separator. The deformation may be any deformation disclosed herein, e.g., cracking and / or material separation. The puncher may cut all edges of a shape (e.g., substantially) simultaneously, e.g., in one punch. As compared to a rotary dicer, the puncher configured to cut a design may be more expensive, since each male-female member pair requires to be custom produced using industrial fabrication, e.g., molding, 3D printing, casting, and / or milling. The thinner the target starting material to be cut, the higher the required precession for fitting the male and female member of the puncher, e.g., otherwise the material will be dragged into a gap between the male and female members, which may cause malfunction (e.g., jam) of the press system (e.g., of the puncher). As compared to manufacturing a die for the rotary dicer, a puncher requires longer processing time for each design, e.g., due to dedicated male-female fabrication of each of the puncher members, which is time consuming, the (e.g., metal) fabrication of the punching parts (e.g., male-female) including molding, 3D printing, casting, and / or milling. The puncher may have a lower durability as compared to the die of a rotary dicer, due to the extent of forces applied during a punch, e.g., to maintain the required gap between the male and female members upon multiple punches without deformation such as due to erosion, friction and / or other wear. The material required for a durable puncher (e.g., male-female pieces) may have higher durability requirement than the material for a die of the rotary puncher. The rotary puncher may be challenging re punching of small feature accurately and / or repeatedly. The rotary dicer may be configured to compress the relief of the die onto the target starting material. The rotary dicer may be configured generate the requested product by minimizing (e.g., avoiding) shearing the target starting material.

[0145] In some embodiments, at least a portion of a cell component is (e.g., further processed) processed via the rotary dicer. The rotary dicer may cut line(s) of requested shape circumference(s) at the interaction area between the die roller and the supporting roller, with the target starting material intervening (and being compressed) therebetween. The reliefed design of the die can be aligned such that a minimal section of the circumference will be cut / debossed at a time, e.g., which will require less force as compared to the punching method that cuts the entire circumference of the shape at a time. The relative force applied to the target starting material by the die roller and by the supporting roller, can be adjusted based at least in part on the geometry to be cut at the time of compression. The force may be exerted by the die roller towards the supporting roller, e.g., a downward motion relative to the gravitational center of the ambient environment in which the rotary dicer is disposed, e.g., Earth. In an example, when cutting short sections such as opposing sides of an electrode disposed normal to the axis of the roller, less force is required (e.g., and applied), as when cutting a line such as an entire side (e.g., Fig. 20, 2002) of the electrode parallel to the axis of the roller. The product (e.g., cuttings) may cheaper to produce with a rotary dicer as compared to with a puncher, e.g., since the component performing the cutting is a sheet / foil coupled with the internal roller of the rotary dicer, forming together the die roller. The rotary dicer may necessitate a shorter processing time for each design, e.g., due to the manufacturing process of the die such as a mask process (e.g., photolithography) and / or embossing - as compared to other industrial fabrication methodologies such as milling, casing, machining, and / or 3D printing. For example, a photolithographic process to manufacture the cutter.

[0146] In some embodiments, a rotary dicer comprises rollers. The rollers may comprise a roller with which a die is coupled, the roller being referred to herein as a “die roller.” The rollers may comprise a die roller and a supporting roller. In an example, the die roller is configured to cut the target material according to the design of the die. In an example, the cutting action by the die occurs as the target material passes through the die roller and its immediately adjacent supporting roller. The die roller may be separated by the supporting roller by a gap. In an example, the cutting action by the die occurs as the target material passes through a gap between the die roller and its immediately adjacent supporting roller. The supporting roller may be configured to support a target material as it is cut by the die roller, e.g., the supporting roller may provide mechanical support (e.g., application of a counterforce), and facilitate the conveyance function of the rotary dicer disclosed herein. The die roller and the supporting roller can be placed at relative adjustable heights. The target may be conveyed into, through, and out of, the rotary dicer. The die roller may rotate relative to the supporting roller disposed adjacent and parallel to the die roller such that a target is pulled by the rotating die roller and supporting roller, to a position between these two rollers,in which position the target is cut by the die. There may be a variable gap between the die roller and supporting roller. The variable gap may be adjustable, e.g., manually and / or automatically such as using a control system. The gap may vary based at least in part on the target material to be cut by the die. The die roller comprises a relief structure, referred to herein as “die” or “cutting die.” A relief structure may be in the form of a sheet or a foil. A relief structure may be wrapped around a surface of an internal roller to collectively form the “die roller.” A roller (e.g., die roller and / or supporting roller) may comprise at least one cylinder, e.g., the roller may comprise concentric cylinders. A relief structure may wrap around the internal roller to form an external surface of the die roller. A relief structure may be coupled with the internal roller such that during its operation, a relief structure may remain (e.g., substantially) stationary relative to the rotating center of the generated die roller.

[0147] In some embodiments, the target starting material comprises a planar material. The planar material may be in a form of a rectangle, e.g., an elongated rectangle. The planar material may be a foil or a sheet. The foil may have a thickness of at most about 2 micrometers (pm), 5 pm, 10 pm, 12 pm, 15 pm, 20 pm, 40 pm, 50 pm, 65 pm, 80 pm, 90 pm, 100 pm, or 200 pm. The foil may have a thickness between any of the aforementioned thicknesses, e.g., from about 2 pm to about 200 pm, or from about 5 pm to about 50 pm. The sheet may have a thickness of more than 0.2 mm, 0.25mm, 0.5mm, 1mm, 2mm, 5mm, or 10mm. The sheet may have a thickness between any of the aforementioned thicknesses, e.g., from about 0.25mm to about 10mm. The planar material may be of an electrode (e.g., a current collector), or of a separator (e.g., a polymer and / or a resin). A particulate material may be operatively coupled with the planar material to form the target starting material. The particulate material may be of an electrode active material, counter-electrode active material, of the separator, or of the divider. The particulate material may have a central tendency of an FLS (e.g., average diameter) of at most about 5 pm, 8 pm, 10 pm, 15 pm, 20 pm, 50 pm, or 100 pm. The particulate material may have a central tendency of an FLS (e.g., average diameter) between any of the above referenced values, e.g., from about 5 pm to about 100 pm, from about 5 pm, to about 50 pm, or from about 5 pm to about 30 pm.

[0148] In some embodiments, the material on which a relief structure (e.g., the die) is flexible. Flexibility of the material used to form the die is configured to allow the die to be wrapped around an external surface of the die roller such that the die is flush with its contacting surface that, upon contacting with the die, forms an internal surface of the die roller.

[0149] In some embodiments, the rotary dicer is configured to manipulate a target at least in part by rotation of its die roller relative to the supporting roller. The rotation direction of the die roller may oppose the rotation direction of the supporting roller. The rotary dicer may be (a) designed with components and / or (b) coupled with a control system, to enable the tworollers (the die roller and supporting roller) to rotate about their respective longitudinal axes relative to each other at a relative velocity, such that (i) a target (e.g., a sheet material) is pulled into the gap between the two rotating rollers, (ii) the pulled target is pulled into the gap between the die roller and the supporting roller from one side wherein the target is cut by the die to generate the requesting cutting and remainder material of the target, and (iii) the cutting(s) is / are expelled from the rotary dicer from an opposing side to the one side. When the target is held by the die roller and the supporting roller at opposing sides of the target, pressure is applied onto the target. The pressure may facilitate cutting of the target at least in part by the die. The mutual rotation of the die roller relative to the supporting roller, may allow the target to (e.g., continuously and / or intermittently) pass between these two rollers, e.g., with minimal intervention. In an example, the target is conveyed continuously between two rollers. The conveyance capability of the rotary dicer can allow the rotary dicer, fitted with a cutting die, to continuously cut (e.g., manufacture) custom shaped components such as for energy manipulation devices including batteries.

[0150] In some embodiments, the rotary dicer comprises roller(s). The roller may comprise elemental metal, metal alloy, an allotrope of elemental carbon, a polymer, or a resin, any plurality of types thereof, or any combination thereof, e.g., such as disclosed herein. In some implementations, the material is (e.g., substantially) the material of a current collector, such as aluminum or copper, e.g., in order to minimize contaminants in the production process. The roller may be comprise (e.g., made up of) material(s) inert to the component(s) of the device they are generated for. An external material of the roller may be comprise (e.g., made up of) material(s) inert to the component(s) of the device they are generated for. For example, an exterior of the roller (e.g., the die, and / or an external coating of the supporting roller) may be materially inert to materials of the cathode and anode structure battery components, such as the cathodically or anodically active materials disclosed herein, comprising NMC, LCO, silicon-compounds, graphite, any plurality of types thereof, or any combination thereof.

[0151] In some embodiments, a relief structure (e.g., functioning as a die) is coupled with an external surface of an internal roller. The die may couple using an adhesive, an attractive force, a mechanical force, or any combination thereof. Any of these coupling methods may be used alone or in combination with any of the other techniques disclosed herein or available in the industry to perform the same function.

[0152] In some embodiments, a relief structure (e.g., functioning as a die) is coupled with an external surface of an internal roller at least in part using an adhesive, e.g., a tacky material. The die may be fitter around the external surface of the internal roller, e.g., and flush with the external surface of the internal roller. The die may couple at least in part via one or more adhesives. The adhesives may comprise an epoxy glue, an industrial tape, or any otheradhesive capable of fitting the die that will allow the die to be (e.g., substantially) stationary relative to the surface of the internal roller with which it is coupled, during operation of the rotary dicer. In some embodiments, adhesives may be (e.g., substantially) irreversible, such that they enable paring of the die to the internal roller for long term use. In other implementations, the adhesive may be a reversible adhesive(s), e.g., as an industrial tape, or an adhesive that leaves negligible residue on the surface of the roller upon removal. In such implementations of a reversible adhesive, the die may be easily removed, readily removed, and / or rapidly replaced, such as with a different die.

[0153] In some embodiments, a relief structure (e.g., a relief sheet functioning as a die) is coupled with an external surface of an internal roller at least in part using an attractive force. The attractive force may comprise a magnetic force, mechanical force, hydraulic force, gas force (e.g., pneumatic force or vacuum), or any combination thereof. In an example, a chuck is employed for mechanical coupling of the die to the internal roller. The chuck may be of any kind suitable to couple the die around the surface of the internal roller. In an example, the chuck may comprise lathe chuck, a collet chuck, a magnetic chuck, a combination chuck, a power chuck, or any combination thereof. The rotary dicer may include a rotary coupling, e.g.., to effectuate the vacuum. The rotary coupling may be operatively coupled with the internal roller that forms together with the die of the die roller. The relief structure (e.g., the die) may be mechanically coupled with the internal roller. The mechanical coupling may comprise at least one fastener (e.g., screw) that hold the die in place. The mechanical coupling may tension the die, e.g., such that the die will (e.g., substantially) remain in place during operation, to generate the requested product (e.g., cuttings and / or debossings) over the prescribed time of operation of the rotary dicer with the particular die.

[0154] In some embodiments, the die is produced. The production of the die may comprise mask related processing, laser shaping, embossing, pressing, stamping, any plurality of method types thereof, or any combination thereof. In some embodiments, embossing is a technique used to create a raised design on a target surface (e.g., a foil or a sheet), at least in part by pressing and / or stamping, the design onto the target surface. The pressing and / or stamping may be by a metal press of the design in one action, and / or in successive action(s). In an example, a shape (e.g. ball shape, or arrow shape) of a hard material (e.g., solid) is pressed onto the target surface in a propagating action along the design to be used as the die knife, e.g., along a circumference of the design to be cut. The die can be produced via a mask-etching technique, e.g., comprising photolithography. A mask may be designed through any design technique complimentary to lithographic processes. For example, Computer Aided Design (CAD) software may define the shape of the mask, and consequently of the die. The mask may be a negative of the requested pattern of cutting edges (e.g., forefront), wherein the cutting edges define the shape of the product cut outfrom the sheet material (e.g., cathode, anode, or separator structures). The cutting edges may form a relief containing structure. The mask may be made of a material complimentary to the etching processes, and intended purposes disclosed herein, e.g., a material inert to a certain electromagnetic region such as ultraviolet region, or infrared region. The mask may be made of a material complimentary to the etching processes, and intended purposes disclosed herein, e.g., a laser light. Use of laser to generate the cutting edge(s) may facilitate an accurate cutting edge, e.g., that can be readily generated. A suitable die material in sheet format may comprise a layer of photoresist, to enable processing techniques disclosed herein. The suitable die material may comprise material properties suitable for the die functions disclosed herein, including relative flexibility and / or a potential for producing (e.g., durable) cutting edges, e.g., over a prescribed lifetime of the device and / or the die, at a prescribed operating condition. The material of the die can vary depending at least in part on the target starting material to be cut. For example, for an organic separator, the die can comprise a harder polymer than that of the separator, a metal, any plurality of types thereof, or any combination thereof. For example, for an electrode, the material can be harder than its current collector material such as comprising elemental metal, metal alloy, any plurality of types thereof, or any combination thereof. For example, the die material may comprise elemental metal or a metal alloy. The metal alloy may comprise stainless steel or Inconel. The metal alloy may comprise a high-performance alloy. The die may comprise a ferromagnetic material, such as steel. The die may facilitate utilization of the adhesive force between the internal roller and the die, e.g., magnetic force. The suitable die material may be dependent at least in part on the target material to be cut. The die mask may be generated by a laser light, e.g., allowing for high precision, high versatility, and quick execution. The die mask may be generated using a reverse masking process, e.g., using light such as Ultraviolet light. The reverse making process may comprise a photoresist mask. The masking process may comprise chemically etching a (e.g., metallic) sheet to generate a relief structure. The time and / or temperature of the chemical etching, the precision of the photopolymerization process (e.g., using layer and / or UV light) may determine the fidelity of a relief structure forming the die. The chemical etching may last a period of time. The etchant may be of variable strengths. The requested height of the edges of the die (e.g., knives created by this process) may be a function of the etching time, etchant strength, and / or etching temperature. A relief structure comprises the knives that are the reliefs. The cutting edges may be sharpened and / or further refined in shape via laser processing techniques to produce a cleaner cutting edge. The die may comprise one or more surface coatings. The die comprises one or more layers of a surface finish. A surface finish may be configured to lower the surface energy of the die. The surface finish may reduce adhesion of (e.g., enable non-stick properties between the die and) the target to be cut. The surfacefinish may comprise a polymer such as Teflon. The one or more surface coating may comprise a polymer or a resin. The die can be produced by an embossing of the relief structure on a sheet or on a foil. The embossed structure comprises an embossed design forming the knives of the die on one surface of the structure. The opposite surface of the structure (e.g., sheet) to the embossing may be filled with a filler material, the opposite surface being a debossed surface. The deposed design may be filled with a filler material. The filler material may comprise (e.g., substantially) the material from which the embossed structure is, from the same type of material, from a different type of material, or any combination thereof. The embossed structure may comprise a first material, and the filler structure may comprise a second material of a different type than the first material. The embossed structure may comprise a first material, and the filler structure may comprise a second material that is (e.g., substantially) the first material. In an example, the embossed structure comprises a metal, and the filler structure comprises that type of metal. In an example, the embossed structure comprises a first metal, and the filler structure comprises a second metal of a different type than the first metal. In an example, the embossed structure comprises a metal, and the filler structure comprises an organic material. The metal may comprise a metal alloy, or an elemental metal. The organic material may comprise a polymer or a resin. The material of the relief structure, the embossed structure and / or the material of the filler of the debossed structure opposing the embossed structure, may comprise an elemental metal, a metal alloy, a polymer, a resin, an allotrope of elemental carbon, a plurality of types thereof, or any combination thereof. The material of the relief structure, the embossed structure and / or the material of the filler of the debossed structure opposing the embossed structure, may comprise a composite material, a non-composite material, a plurality of types thereof, or any combination thereof. The relief structure, the embossed structure and / or the material of the debossed structure opposing the embossed structure, may comprise one or more layers. The external layer functioning as the die may compromise one or more layers that minimize adhesion of the target starting material to the die, e.g., during the cutting process. The external layer of the die may comprise Teflon (e.g., polytetrafluoroethylene PTFE), polyfluoroalkyl, perfluoroalkyl substances (PFAS) (e.g., perfluorooctanoic acid (PFOA)), non-stick ceramic coating (e.g., comprising silicon dioxide SiC>2), carbon steel, stainless steel, silicone, Gore-Tex (e.g., extended, or stretched PTFE such as ePTFE), siloxane (e.g., polydimethlsiloxane (PDMS)), silane (e.g., organoalkoxysilanes), oxidized regenerated cellulose, any plurality of types thereof, or any combination thereof.

[0155] In some embodiments, the die is generated, the die comprising elevated structures relative to the surface of the die adhering to the internal surface of the die roller, e.g., using magnetic force. The die may comprise one or more relief types. The one or more relief typesmay comprise a knife, a press, any multiple types thereof, or any combination thereof. The knives (e.g., Fig. 17, 1705) may be of different shapes, different heights (e.g., Fig. 17, 1752), and / or different angles (e.g., Fig. 17, 1750) relative to the non-reliefed plane of the die (e.g., Fig. 17, 1751). The different angles may comprise angles may comprise normal and / or obtuse angles. The different angles (e.g., 1750) may comprise an angle of at least about 90 degrees (°), 120°, 130°, 140°, 150°, 160°, or 170°. The different angles may be of any value between the aforementioned values, e.g., from about 90° to about 170°. The relief structure may cause one cutting and / or sunken (e.g., indentation) effects on the target starting material, upon compression of the die onto the target starting material. The relief may comprise a low relief (e.g., bas-relief), a high relief (e.g., alto relief), any types thereof, or any combination thereof. The low relief may rise from the surface of the die by up to a half of the thickness of the thickness of the die, the thickness of the die excluding the relief structure. The high relief may rise from the surface of the die by a height more than half of the thickness of the die, the thickness of the die excluding the relief structure. The relief may be of a height of at least about 2% 5%, 10%, 20%, 50%, 80%, or 100% of the thickness of the die excluding the relief structure. When the die is pressed upon the target starting material it may fully and / or partially penetrate into the target starting material (e.g., sheet material to be cut). When the die is pressed upon the target starting material it may generate cuttings, depression, or partial cutting. The partial cutting may be generated using a cut that is incomplete. The incomplete cut may include a dotted line and / or a dashed line, where the dots and / or dashes are completely cut, and the other portions of the incomplete cut are uncut. The pressing of the die onto the target starting material may generate a depression, debossing, imprint, a sunken relief, indentation, any plurality of types thereof, or any combination thereof. The pressing of the die that does not result in generation of a cut in the target starting material, may be processes by other means such as disclosed herein, e.g., laser processing. In an example, large structures may be cut by the die, and small structures may be pressed by the die, and left for other processing type(s). The other processing type(s) may process portions of the design that are more difficult to (e.g., accurately) cut with the die. In an example, the other processing type(s) cut portions of the die that may be more difficult to separate from the die upon their complete cutting by the die, e.g., alignment features, engagement features, and / or object with sharp (e.g., acute) angles such as disclosed herein. The sharp angle may be at most about 90°, 60°, 30°, 15°, 10°, or 5°. The sharp angle may be of any value between the aforementioned values, e.g., from about 90° to about 5°. The one or more features to be cut by the die, may have rounded edges, e.g., to allow for easier removal of the cuttings from the die. The cuttings may be separated from the die using a force, e.g., gravitational force of the ambient environment (e.g., Earth), attractive force such as disclosed herein (e.g., magnetic, vacuum, and / or static electricity), pushingforce (e.g., gas stream), any combination of types thereof, or any combination thereof. Edges of die may be designed to lessen adhesion and / or clinging of the target starting material to the die after operation of the die on the target staring material. Corners of the relief of the die may have rounded corners rather than hard edges such as having the sharp angles.

[0156] In some embodiments, the die comprises one or more die aligners. The die aligners may be used align coupling of the die with the internal roller, e.g., using mechanical adhesion. The aligner may comprise any aligner structure disclosed herein, e.g., the die aligner may comprise a slit or a notch, used to align the die onto the surface of the roller, e.g., as the die wraps around the roller. Similarly, the aligner may be an aperture, to allow fasteners (e.g., screws) to pass through the die and into the roller of the die roller to hold the die in place during operation. The die aligners may or may not be an aligner of the electrodes and / or separator.

[0157] In some embodiments, the rotary dicer comprises the supporting roller. The supporting roller may (e.g., wholly) comprise a polymer, a resin, a composite, a noncomposite, a ceramic, an elemental metal, a metal alloy, an elastomer (e.g., rubber), an allotrope of elemental carbon, a plurality of types thereof, or any combination thereof. In some embodiments, the polymer comprises plastic, or any other material disclosed herein for the external layer of external layer functioning as the die such as disclosed herein. The supporting roller may comprise layers. An external surface of the supporting roller may comprise any other material disclosed herein for the external layer of external layer functioning as the die such as disclosed herein. The supporting roller may comprise a surface layer of the aforementioned materials. The metal alloy may comprise stainless steel, or Inconel. The metal may comprise aluminum or copper. During operation of the device, the die may puncture the supporting roller. The supporting roller can comprise an exterior surface including an elastic and / or quickly mendable material, e.g., after being punched or cut by a cutting edge such as the cutting edge of the die. The supporting roller may (e.g., wholly) comprise or comprise self-healing material(s), such as self-healing polymers. The self-healing polymers may comprise polyurethanes, poly(urea-urethane), a Diels-Alder adduct, any plurality of types thereof, or any combination thereof. The supporting roller may (e.g., wholly) comprise material(s) having dynamic covalent and / or supramolecular interaction, which enable quick repair after surface damage, e.g., such as materials having labile polar and / or hydrogen bonds. The supporting roller may include any of these materials in its surface, e.g., surface layer. Material layer(s) may be added to the surface of the supporting roller, e.g., applied as coating(s) and / or coupled with the axis of the supporting roller by any coupling mechanisms such as disclosed herein. For example, the coupling may comprise adhesion, such as by an adhesive material that may be a (e.g., substantially)irreversible adhesive (e.g., epoxy), and / or by mechanical coupling. The supporting roller may be made from a material inert to the component being produced and / or to its designated device such as for energy manipulation, e.g., battery. The supporting roller may be inert to cathodically, anodically active materials, and / or processes occurring in the energy manipulation device. The processes may occur during its storage, maintenance, buffering, transportation, and / or use. The supporting roller material (e.g., external material contacting the target to be cut) may or may not be harder than the material from which the die is made. The supporting roller (e.g., the surface layer of the supporting roller) may comprise any of types of materials disclosed herein suitable for intermittent and / or continuous cutting via the cutting die, such as over the prescribed lifetime of the rotary dicer under prescribed (e.g., normal) operation.

[0158] In some embodiments, the die roller is rotating with respect to the supporting roller. The die roller and the supporting roller may each rotate in an opposite direction along their longitudinal axis, e.g., in a concerted and / or coordinated fashion such as using a control system and actuator(s). The die roller may rotate while the supportive roller remains stationary.

[0159] Fig. 12 depicts an example of a rotary dicer processing a target starting material to generate a remainder 1204, the target starting material comprising a sheet or a foil. The rotary dicer produces target product in the form of cuttings 1205 of the target starting material. Cuttings 1205 are shaped in accordance with the circumference pattern of die 1203. Cuttings 1205 may be battery components (e.g., cathode structure, anode structure, or separator). The rotary dicer comprises two parallel rollers, a die roller 1201 and a supporting roller 1202. The two rollers are coupled to a structural frame (not shown). Die roller 1201 and supporting roller 1202 each include a shaft or an axel 1206a and 1206b respectively, along each roller’s respective longitudinal axis. Each of the two rollers rotates in an opposite direction to one another, as depicted by arrows 1210a and 1210b. The one direction may be a clockwise direction, and the other direction may be a counterclockwise direction, or vice versa. In an example, the direction of rotation may determine the direction from which the target starting material is pulled into the rotary dicer, and a direction from which product is expelled from the rotary dicer. The product may comprise cuttings and / or debossings. The product may comprise a plurality of members.

[0160] In some embodiments, the rotary dicer is coupled to a frame. The frame may enable the rotary dicer to be maneuverable. Maneuverability of the rotary dicer may be lateral, in, or in an angle relative to the floor. The rotary dicer may be maneuverable manually and / or automatically, e.g., using a control system. The frame may be made of a durable, loadbearing material, e.g., complimentary for applications of the inventions disclosed herein. For example, the material of the frame may comprise elemental metal, metal alloy, polymer,resin, or an allotrope of elemental metal, any plurality of types thereof, or any combination thereof. The material of the frame may include a composite and / or a non-composite material. The metal alloy may comprise stainless steel or Inconel. Fig. 13 depicts a perspective view of a structural frame component having stage 1301 to which the rotary dicer may be called, the stage capable of being maneuvered along tracks 1302, and using wheels such as 1303. Stage 1301 can pivot at an angle along bent arrow 1304, causing the rotary dicer affixed to stage 1301 to pivot in that angle.

[0161] In some embodiments, the rotary dicer comprises rotating rollers. The rotating rollers may comprise, or operatively couple with, bearings. Rotation of a roller of the rotary dicer may be enabled at least in part by coupling bearings that minimize friction during rotation of the roller, e.g., to allow for smooth rotation. The bearings may comprise air bearings, or ball bearings. The bearings may couple with an end of a shaft to the (e.g., motorized) structural framework.

[0162] In some embodiments, the die roller and the supporting roller may be oriented such that the rotational axis of one of these rollers is relatively parallel to the rotational axis of the other of these rollers, the rotational axes being their longitudinal axes. The die roller and the supporting roller, may each be positioned at defined, adjustable heights along the structural frame. Between the die roller and the supporting roller may be a gap of a defined (e.g., and adjustable) width. The gap may be a dynamic gap. The gap may be adjustable at least in part on (a) the thickness of the target to be cut and / or (b) the material makeup of the target to be cut. The material makeup may comprise the current collector, the active material coupled with the current collector, the separator (e.g., any layers of the separator), or any combination thereof. The rotary dicer may be equipped to independently rotate the die roller and the supporting roller, e.g., at controlled speeds and directions. The control may comprise manual and / or automatic control, e.g., using a control system. The roller may be coupled with an actuator such as a motor. The motor may comprise a servo motor. The actuator may cause rotation of the roller through any mode of actuation that allows for the motor to (e.g., smoothly) rotate the roller with which it is coupled, about the roller’s longitudinal axis. The actuator may be directly coupled to the roller. The actuator may be coupled to the roller using one or more gears. At least one actuator of the rotary dicer may be coupled to both die roller and supporting roller. The die roller and supporting roller may each be coupled to at least one different actuator. The mode of actuation of an applicable actuator may be any that enables the motor to accomplish said rotation of the roller. For example, the mode of actuation may be electrical, hydraulic, pneumatic, magnetic, any plurality thereof, or any combination thereof. An electric servo motor may rotate one roller (e.g., a roller die) in a first direction (e.g., clockwise) at a first rotational speed, and a second roller (e.g., a support die) in a second direction that is opposite to that of the first (e.g.,counterclockwise). The rotation of the rollers may be such that any target material in a sheet or in a foil format may pass between both rollers in a manner of conveyance. The die roller may be operatively coupled to the supporting roller at least in part using gear system comprising one or more gears. The die roller may be operatively coupled to the supporting roller at least in part using an actuator system comprising one or more actuators.

[0163] In some embodiments, the target starting material for the cutting is a material sheet or foil. The target starting material may be configured for roll-to-roll manufacturing. The target starting material is for forming components of an energy manipulation device such as battery component. The components may be cell components. The cell components may include anode, cathode, divider, and / or separator. The cell components may include anode current collector and / or cathode current collector. The target starting material may include an anode collector coupled with an anode active material and / or a cathode collector coupled with a cathode active material, e.g., the coupling may be facilitated at least in part by coating the active material on the current collector to generate the target starting material. The target starting material may generate a remainder (e.g., Fig. 12, 1204) and cuttings (e.g., Fig. 12, 1205) after begin processed by the rotary dicer. The thickness of the target starting material may be at least about 3 micrometers (pm), 5 pm, 10 pm, 12 pm, 15 pm, 18 pm, 20 pm, 50 pm, 80 pm, 90 pm, 100 pm, 250 pm 500 pm, 800 pm, or 1000 pm. The thickness of the target starting material may be at most about 1500 pm, 1000 pm, 800 pm, 500 pm, 250 pm, 100 pm, 90 pm, 80 pm, 50 pm, or 20 pm. The thickness of the target starting material may be any value between the aforementioned values, e.g., from about 3 pm to about 1500 pm, from about 3 pm to about 250 pm, or from about 80 pm to about 1500 pm. The gap between the die roller and the supporting roller may be at least about 3 micrometers (pm), 5 pm, 10 pm, 12 pm, 15 pm, 18 pm, 20 pm, 50 pm, 80 pm, 90 pm, 100 pm, 250 pm, 500 pm, 800 pm, or 1000 pm. The gap between the die roller and the supporting roller may be at most about 1500 pm, 1000 pm, 800 pm, 500 pm, 250 pm, 100 pm, 90 pm, 80 pm, 50 pm, 20 pm, 15 pm, 10 pm, or 5 pm. The gap between the die roller and the supporting roller may be any value between the aforementioned values, e.g., from about 3 pm to about 1500 pm, from about 3 pm to about 20 pm, from about 3 pm to about 50 pm, from about 3 pm to about 100 pm, from about 3 pm to about 250 pm, or from about 80 pm to about 1500 pm. The die roller is separated from the supporting roller by the gap. The gap may depend at least in part on the relief height of the die, e.g., on the height of the cutting edges (e.g. Fig. 17, 1705), the material, and requested pressure. In an example, a width of the gap is the distance between the die roller and the supporting roller, which gap width is configured to accommodate the target starting material that is destined for cutting by the die. The width of the gap may be targeted between the die roller and the supporting roller. The gap may be (e.g., substantially) the same as, or smaller than, the thickness of the target starting material. The gap width maybe smaller than the thickness of the target starting material by at most about 1%, 2.5%, 5%, 10%, or 20%. The gap width may be smaller than the thickness of the target starting material by at least about 0.5%, 1%, 2.5%, 5%, 10% or 15%. The gap width may be smaller than the thickness of the target starting material by any value between the aforementioned values, e.g., from about 0.5% to about 20%, from about 0.5% to about 10%, or from about 5% to about 10%. An exterior surface (e.g., and an interior) of the supporting roller opposing the die, is made of a material (a) stronger than the die, (b) otherwise more robust that the die with respect to scratches or puncture occurring during the dicing process, and / or (c) mendable after being scratched and / or punctured during the dicing process (e.g., a self- healing material). In an example, a sheet of current collector material may be coated with its respective active material (e.g., as a slurry), which is subsequently dried, compressed, and calendered. The slurry may comprise a formulation providing adhesive properties such that the active material (e.g., particulate material) adheres to itself, and adheres with the current collector. Such may be configured to withstand the manufacturing process, e.g., by the rotary dicer. The target starting material may experience tension as it is pulled into the gap between the die roller and the supporting roller. The tension experienced by the target starting material as it passes (and is cut) by the die, can be at least about 1 Newtons (N), 2N, 3N, 4N, 5N, or 6N. The tension experienced by the target starting material as it passes (and is cut) by the die, can be at most about 3N, 4N, 5N, 6N, 7N, 8N, 9N, or 10N. The tension experienced by the target starting material as it passes (and is cut) by the die, can be of any value between the aforementioned values, e.g., from about 1 N to about 10N, from about 3N to about 5N, from about 1 N to about 5N, from about 5N to about 10N, or from about 3N to about 5N. The die may be configured such that the total force required for the cutting edges (e.g., Fig. 17, 1705) to cut sheet material may need to be beyond the yield strength of the sheet material. Assuming a negligible blade mass, the applied force may be a component of the centrifugal force in the blade section of at most about most about 3N, 4N, 5N, 6N, 7N, 8N, 9N, or 10N. During operation, the reaction force in the rotary dicer may results in compressive shearing. In an example, the force required to make a cut by the die (e.g., with a cut width of 0.2 mm, and a lateral a length of 100mm along the lateral axis of the die roller), may result in a compressive strength of at most about 5 megapascals MPa, 10 MPa, 15 MPa, 18 MPa, 20 MPa, or 30 MPa; the force may be at most about 200Newton (N), 300N, 400N, or 500N. The compression and the force may be any value between the aforementioned values, e.g., compressive strength of from about 5MPa to about 30 MPa, and force from about 200N to about 500N. The tension may (e.g., continuously) change as the target starting material (e.g., sheet) is conveyed through the rotary dicer. During processing of the target starting material, applied pressure on the target starting material by the rotary dicer may be dynamic and / or controlled. The control may be automatic, e.g., usinga control system such as disclosed herein. The pressure may be sensed, e.g., by one or more sensors including pressure sensor and / or movement sensor. The control system may utilize a closed loop control and / or an open loop control scheme to control the rotary dicer, e.g., the pressure applied on the target material. In some embodiments, the tension is applied to the sheet material is different and / or deliberate amounts. The open loop control may utilize a physics simulation. The physics simulation may consider the material makeup of the target starting material, and / or one or more physical properties of the target starting material. The material makeup may comprise of chemical makeup, e.g., as disclosed herein. The material makeup may comprise a physical phase. The physical phase may comprise a solid, a semisolid, a sheet, a foil, or a particulate material. The one or more physical properties may comprise brittleness, elasticity, strength, stretchability, compressibility, or any combination thereof. In an example, the rotary dicer may be setup to a specific gap between the die roller and the supporting roller. In the case of cutting (e.g., an anode), the gap may be slightly less than the full thickness of the target starting material. The tension in the die may be from about 3 to about 5N. The applied force by the die to the target started material may be a component of the centrifugal force in the blade section (e.g., of at most about 10N, assuming a light blade mass) and a reaction force that results in the compression, e.g., resulting in cutting. The force that the die experiences can be approximately the average of the compressive strength of the target starting material. In an example, assuming a cut width of 0.2 mm and a length of 100mm, and a compressive strength of ~18 Mega Pascals (Mpa), the force required to cut the starting material would be about 400N.

[0164] In some embodiments, one or more components of the rotary dicer are controlled. The control of the component (e.g., relative height, pressure, and / or rotational velocity) may be dynamic, e.g., manual and / or automatic. The automatic control may comprise usage of a control system such as disclosed herein. For example, the control may be based at least in part on the design, the section to be cut at engagement, and / or the section to be debossed at engagement, the engagement being of the die roller and of the supporting roller, with the target starting material compressed therebetween, e.g., the section to be cut in a horizontal (e.g., line like) section, begin the portion of die facing the top portion of the supporting roller. The compression depth of the die into the target starting material may be variable. The compression depth may vary based at least in part on (a) the extent of relative compression between the die roller and the supporting roller, (b) the relative height of the relief portions in the die. The relief portions of the die may be (e.g., substantially) of the same height, or of different heights. During the relative revolution of the die roller and the supporting roller, some portions of the die facing the supporting roller may be (e.g., substantially) of the same height. During the relative revolution of the die roller and the supporting roller, some portions of the die facing the supporting roller may be of different heights.

[0165] In some embodiments, the target starting material is a multi-layered material. The multi-layered material may be a tri-layered material. The tri-layer material may comprise a first layer of active material disposed on one side of a current collector, the current collector, and a second layer of active material disposed on an opposing side of the current collector. The force that the sheet material experience is approximately the average of the compressive strength of the tri-layer area. The first layer of active material may or may not be of the same type as the second layer of active material. The first layer of active material may comprise anode active material, and the second layer of active material may comprise anode active material. The first layer of active material may comprise cathode active material, and the second layer of active material may comprise anode active material. The first layer of active material may comprise cathode active material, and the second layer of active material may comprise cathode active material.

[0166] In some embodiments, the rotary dicer comprises a die roller and a supporting roller rolling in opposite directions with respect to each other during the dicing process. The rotational velocity of each roller, and the resulting speed of conveyance, may influence the extent (e.g., amount) of target starting material (e.g., sheet material) that adheres to the die, e.g., as a result of the curing process. Such adhesion may be an unwanted adhesion. Such adhesion may be corners (e.g., sharp corners) of a relief design (e.g., knives) of the die. At times, a relief design is configured to reduce (e.g., eliminate) occurrence of acute (e.g., sharp) angles. Acute angle in the originally requested design may be exchanged by a curvature in a relief design forming the cutting edge(s) (e.g., knife(s)) of the die.

[0167] In some embodiments, one or more parameters of the rotary dicer may be predefined. The one or more parameters may comprise (a) a position of each roller of the rotary dicer, (b) the gap between two immediately adjacent rollers, (c) the applied pressure to the target starting material to be processed by the rotary dicer, (d) the rotational velocity of each roller, (e) the speed of conveyance of the target starting material, (f) relative position of the rotary dicer in space (e.g., relative to a floor of a facility in which the rotary dicer is disposed), (g) the applied torque to any roller of the rotary dicer, (h) any other structural parameters, (i) any functional parameters, or (j) any combination thereof. The parameter(s) may be manually and / or automatically defined, e.g., using a simulation comprising a physics simulation. The parameter(s) may be manually and / or automatically controlled, e.g., using a simulation comprising a physics simulation. A control system such as the control system disclosed herein, or any control system designed to centralize control of any structural and / or functional parameters of the rotary dicer, may be employed for the aforementioned purposes. The control systems may be coupled to one or more (a) control devices, (b) controllable components, (c) sensors, and / or (d) energy sources. The controllable devices may comprise actuators (e.g., motors), sensors, measurement systems, stop systems, anyplurality of types thereof, or any combination thereof. The sensors may comprise temperature sensors, movement sensors, pressure sensors, torque sensors, velocity sensors, proximity sensors, compression sensors, tension sensors, optical sensors (e.g., camera), height sensors, angular sensors, positional sensors, chemical sensors, any plurality of types thereof, or any combination thereof. The velocity sensors may comprise linear velocity sensors, rotary velocity sensor, or any combination thereof. The optical sensors may comprise a Charge Coupled Device (CCD) camera. The camera may be configured to take stills or video. The optical sensors may be configured to detect optical signals in the ultraviolet region, visible region, infrared region and / or X-ray region. The positional sensors may comprise GPS. The chemical sensors may be utilized for infrared spectroscopy, or Raman spectroscopy. The one or more sensors may comprise laser, e.g., utilize laser radiation.

[0168] In some embodiments, the rotary dicer comprises one or more actuators, e.g., motors such as the ones disclosed herein such as servo motors. The actuator(s) may be fitted to (e.g., automatically) adjust the relative rotational velocity, rotational acceleration, torque, and / or height of any roller of the rotary dicer, e.g., the die roller and / or the supporting roller, the gap width, the applied torque, the rotational speed of the die roller and / or of the supporting roller. The rotary dicer may comprise a piezoelectric drive and / or an encoder, e.g., measuring micrometer and / or nanometer scale movements. The encoder may comprise a magnetic encoder, or an optical encoder, a magnetic encoder, an inductive encoder, a linear encoder, a rotary encoder (e.g., absolute or incremental), an absolute encoder, any plurality of types thereof, or any combination thereof. The rotary dicer may comprise, or may utilize, a sprit level, a digital inclinometer, and / or a laser alignments tool, e.g., used to calibrate the horizontal placement of the rollers, e.g., the rotational axis thereof.

[0169] In some embodiments, the rotary dicer comprises and / or is operatively coupled with one or more sensors, e.g., as disclosed herein. The sensors may monitor one or more parameters associated with (e.g., of) the rotary dicer. Any other measurement devices, systems, or combinations thereof, which are designed to control (e.g., monitor) and / or measure, the one or more parameters may be utilized. As disclosed herein, control may comprise regulate, modulate, adjust, maintain, alter, change, govern, manage, restrain, restrict, direct, guide, oversee, manage, preserve, sustain, restrain, temper, or vary. The control may include continuous and / or intermittent control. The sensors may continuously and / or intermittently, record their measurements. The sensors may operatively couple with the control system and send the measurements to the control system, e.g., continuously and / or intermittently. In response, the control system may (e.g., continuously and / or intermittently) send signals to the appropriate components fitted throughout the rotary device to adjust any of the functional aspects of the rotary dicer, e.g., to meet the requested valuesfor any of the functional aspects of the rotary dicer. For example, the control system may receive signal that the applied pressure is dropping and / or the calculated gap width is increasing; and, in response, signal motors responsible for relative roller height adjustment, to close / open the gap width until a requested gap width value is reached, e.g., restored. Stopping devices and / or stopping systems may be implemented such that when the control system receives (e.g., live) measurements that, for a particular functional aspect, exceed a threshold, the control system may signal appropriate devices and / or the rotary dicer to halt operation. The threshold may comprise a value, a function, or a window. When the control system receives measurements from a sensor that a safety threshold is violated, or is about to be violated, the control system may take remedial action(s) to reduce the likelihood (e.g., prevent) that the safety violation occurs / continues, e.g., turn off operation of the rotary dicer to prevent operation that may be hazardous. The sensor may detect that hazardous condition(s) is / are occurring or are imminent. Hazardous may be to the rotary dicer device, to the target staring material, to the resulting cuttings, to personnel adjacent to the rotary dicer, to the facility in which the rotary dicer is disposed, to the environment in which the rotary dicer is disposed, or any combination thereof. In an example, when the control system receives measurements from a temperature sensor that the instrument temperature or roller temperature violates (e.g., exceeds) a temperature threshold, the control system turns off operation of the rotary dicer to hinder (e.g., prevent) operation of the rotary dicer in a way that may be hazardous. Hazardous may be to the rotary dicer device, to the target staring material, to the resulting cuttings, to personnel adjacent to the rotary dicer, to the facility in which the rotary dicer is disposed, to the environment in which the rotary dicer is disposed, or any combination thereof.

[0170] In some embodiments, the rotary dicer is employed after target starting material including a cell component, has undergone one or more processing operations, e.g., calendering or any other fabrication process such as disclosed herein. A coating operation of coating a slurry may apply the respective active material coating to a current collector to generate an electrode, which is cathodic or anodic nature. The slurry may comprise a dry slurry or a wet slurry. Different types of slurries may be applied to a sheet to generate the target starting material. The electrode may be dried in at least one drying operation, e.g., using any tools and techniques to aid in drying an electrode such as using an oven. The compressive roller may compress the active material of the electrode to increase the density its active material, e.g., the active material deposited on a sheet of current collector material to generate the target starting material for the rotary dicer. The compressive roller (e.g., in a calendering function) may increase uniformity of the thickness of the active material coupled with the current collector sheet / foil, to form the target starting material. The density of the active material layer may be at least about 0.5 grams per cubic centimeters (gr / cc), 0.7 gr / cc,0.75 gr / cc, 0.8 gr / cc, 0.85 gr / cc, 0.9 gr / cc, 1.0 gr / cc; 2.5 gr / cc, 2.95 gr / cc, 3.15 gr / cc, 3.5 gr / cc, 4 gr / cc, 4.2 gr / cc, 4.5 gr / cc, 6 gr / cc, 6.5 gr / cc, or 7 gr / cc. The density of the active material layer may be at most about 0.6 gr / cc, 0.7 gr / cc, 0.75 gr / cc, 0.8 gr / cc, 0.85 gr / cc, 0.9 gr / cc, 1.0 gr / cc; 2.5 gr / cc, 2.95 gr / cc, 3.15 gr / cc, 3.5 gr / cc, 4 gr / cc, 4.2 gr / cc, 4.5 gr / cc, 6 gr / cc, 6.5 gr / cc, 7 gr / cc, or 10 gr / cc. The density of the active material layer may be of any value between the aforementioned values, e.g., from about 0.5 gr / cc to about 10 gr / cc, from about 0.5 gr / cc to about 2 gr / cc, or from about 3.5 gr / cc to about 7 gr / cc. The density of the cathode active material may be higher that the density of the anode active material layer by at least about 1.5*, 2*, 3*, 4*, or 5*, “*” designating the mathematical operation of “times.” The density of the cathode active material may be higher that the density of the anode active material layer by at most about 2*, 3*, 4*, or 5*. The density of the cathode active material may be higher that the density of the anode active material layer by any value between the aforementioned values, e.g., from about 1.5* to about 5*, or from about 1.5* to about 3*. The thickness of the target starting material may be of any value disclosed herein. The compressed and / or calendared active material may have an Ra value of at most about 1.5 micrometers (pm), 3 pm, 10 pm, 5 pm, 8 pm, 17 pm, 20 pm, or 50 pm. The compressed and / or calendared active material may have an Ra value between any of the aforementioned values, e.g., from about 1.5 pm to about 50 pm, or from about 3 pm to about 20 pm. Ra is the arithmetic mean of the absolute values of the surface eight deviations within a specified sample length, e.g., roughness average. The rotary dicer may include additional roller(s) to the die roller and to the supporting roller. The additional roller(s) may include a compression roller and / or a calender roller. The rotary dicer may be operatively coupled with the additional roller(s). The compressive roller may function as a calendering device, e.g., to calender the thickness of the target starting material, e.g., to calender a layer of active material coupled with a current collector to form the target starting material. The compression and / or calendering roller(s) may at least in part generate the target starting material to be fed to the rotary dicer. At least two of the rollers of the rotary dicer may have (e.g., substantially) the same diameter. At least two of the rollers of the rotary dicer may have (e.g., substantially) different diameters. At least two of the rollers of the rotary dicer may have (e.g., substantially) the same lateral length portion configured to contact a target starting material. At least two of the rollers of the rotary dicer may have (e.g., substantially) different lateral length portions configured to contact a target starting material.

[0171] In some implementations, the calendering device may operate at range. The temperature range may include, or exclude, the ambient temperature. The device may be disposed in an ambient environment having the ambient temperature. The device may be disposed in a different environment different from the ambient environment. The different environment may differ from the ambient environment by one or more environmentalcharacteristics comprising temperature, atmospheric makeup, pressure, or any combination thereof. Relative to the ambient environment, the different environment may have a reduced concentration of one or more reactive agents (also referred to herein as “reactive species”). The reactive agent(s) may comprise oxygen, water, alcohol, thiol, sulfuric acid, phosphoric acid, carboxylic acid, hydrogen sulfide, any plurality thereof, or any combination thereof. The reactive agent(s) may be oxygen based, sulfur based, and / or phosphorous based. The reactive agent(s) may include water and / or oxygen. In an example, the reactive agent(s) comprise water in a liquid and / or vapor form. The different environment may be an inert environment that is inert (a) to the target starting material being diced by the rotary dicer and / or or (b) to processes (e.g., chemical processes) occurring in the energy manipulation device such as battery. The different environment may be at a temperature (e.g., window) different from that of the ambient temperature. The rotary dicer and / or the compression (e.g., and calendering) roller may operate at a temperature range different from and / or excluding the ambient temperature. The different temperature (e.g., range) may comprise elevated temperatures. The calendered electrode may be fed into the rotary dicer. The one or more parameters of the rotary are configured to cut the cuttings out of the target starting material, e.g., without further modification to the thickness of the target starting material. A central tendency (e.g., average) of the thickness of a region of a target starting material may be (e.g., substantially) the same as the corresponding region in the resulting cuttings. The one or more parameters of the rotary dicer may comprise the operating gap width, the pressure, the temperature, or any other parameter(s) disclosed herein. In some embodiments, the rotary dicer operates in an inert environment, an environment having reduced percentage of reactive species (e.g., oxygen or water), or any other environment inert to the target starting material being processed.

[0172] In some embodiments, the rotary dicer is part of a multi-step fabrication process, e.g., as disclosed herein. The separation of the rotary dicer from prior processing of the multi-step fabrication process, may be physical. The rotary dicer may be located in a different processing (e.g., manufacturing) line. The different processing line may utilize separate and different machine types - also referred to herein as “tools.” The different tools may utilize a separate structural frameworks. In an example, the tools comprise the rotary dicer and the calendering device. In an example, the rotary dicer employs a first framing (e.g., structural framework) and is located in a first fabrication line, while the calendering device employs a second framing and is located in a second fabrication line. One or more tools may be utilized in the multi-step fabrication process. At least two of the tool(s) may use the same framing. At least two of the tool(s) may be located in the same fabrication line. At least two of the tool(s) may be located in different fabrication lines. At least two of the tool(s) may utilize different framings. At least two of the tool(s) may be operatively coupled, e.g.,using a control system such as disclosed herein. At least two of the tool(s) may be controlled sequentially, in concert, in parallel, or independently from each other. A first tool operating a first process may be physically separated from a second tool operating a second process, e.g., while being coupled within the same framing. The rotary dicing process may be physically separated from at least one other processes, while being coupled within the same framing. The other processes may comprise processes that the target material undergoes prior to, simultaneously with, and / or after, the cutting operation by the rotary dicing. The other processes may comprise deposition, compression, calendering, roll-to-roll, cutting, forming, machining, welding, punching, casing, depositing, drying, spraying, 3D printing, calendering, compressing, ablating, dicing, adhering (e.g., gluing), soldering, any plurality of types thereof, or any combination thereof. For example, the same framing may comprise a pair of rollers couple to function as a compression and calendering operation, and another pair of rollers (e.g., a die roller and supporting roller) functioning as the rotary dicer to dice the compressed and calendered target stating material and generate the requested cuttings and remainder material. In another embodiment, the same framing may be used for compressing, calendering and rotary dicing, e.g., by adding one or more additional rollers to the structural framework of the rotary dicer, wherein the one or more additional supporting rollers are different from the die roller. In some embodiments, the supporting roller supports more than one roller. The more than one roller may include the calendering roller, the compressing roller, and / or the die roller. The rotary dicer may calender and cut the target starting material simultaneously via the die roller and the supporting roller. The rotary dicer may compress, calender and cut the target starting material simultaneously via the die roller and the supporting roller. The calendering and / or compression may be accomplished by altering (e.g., decreasing or increasing) the gap between the die roller and supporting roller, such that as the target starting material is conveyed through the gap, the rotary dicer simultaneously (optional compresses) calenders and cuts the sheet material via the die. The applied pressure is utilized to simultaneously (optionally compress), calender, and cut, the target starting material. Such multi-functionality of the rotary dicer may be based at least in part on maintaining a defined height of the die roller with respect to the supporting roller. A height control system may operate by defining a gap width onto the sheet material. Such multi-functionality of the rotary dicer may be based at least in part on maintaining a defined pressure on the target starting material by the die roller with respect to the supporting roller. A pressure control system may operate by defining a gap width onto the target starting material, e.g., the sheet of material. The calendering and / or compression system may operate by dynamically applying variable force onto the target starting material as it is conveyed through the gap, such that the gap width is maintained and the target starting material is pressed to a uniform thickness. The rotary dicer may maintain the thickness ofthe cutting (e.g., battery component) being produced. The control system utilized by such rotary dicer may be any control system disclosed herein, e.g., using pressure sensors, location sensors, and / or height sensors. One or more additional rollers may be added, e.g., to help planarize the target starting material being fed into the rotary dicer portion that performs the cutting action. The height control system and / or the pressure control system may be part of a control system, such as disclosed herein.

[0173] In some embodiments, pressure is controlled by the rotary dicer. The pressure can be pressure of the die roller with respect to the supporting roller, or between any other two immediately adjacent rollers of the rotary dicer, e.g., as disclosed herein. The rotary dicer may operate at least in part to control (e.g., maintain) a pre-defined pressure applied to the sheet material, e.g., independent of the gap width, or dependent on the gap width.

[0174] In some embodiments, one or more other cutting methodologies and / or processes may supplement a manufacturing line. The one or more other cutting methodologies may include punching and / or laser processing. The one or more other cutting methodologies may occur before, during, or after cutting of the target starting material by the rotary dicer. The one or more other cutting methodologies may occur before, during, or after feeding the target starting material to the rotary dicer. In an example, laser processing can be used to cut small features that may be difficult to remove from the die using a rotary dicer.

[0175] In some embodiments, the target starting material is cut into the requested cuttings. The cutting may be utilized as device (e.g., cell) components. The cuttings may undergo further processing, e.g., comprising cleaning. Cathode structure or anode structure battery components may undergo cleaning, e.g., to remove any excess or unwanted active material layer from a predetermined location of the product, mechanical and / or chemical methodologies may be utilized for the further processing. The further processing may include addition of solvent to remove excess material and / or wiping action. The target material may comprise a coating that allows the target starting material (e.g., particulate material thereof) to withstand the cutting process without substantial harm. The coating may comprise any coating disclosed herein, e.g., for use in the die. The substantial harm relates to a measurable harm that would cause the active material to not perform according to its requested and / or designed specification in the final product for which it is designed.

[0176] Fig. 14 is a perspective view of a portion of the rotary dicer. Die roller 1410 is vertically stacked above supportive roller 1411, and both rollers are coupled to framing 1413 - a structural framework. Height adjustment structures 1402a and 1402b are configured to adjust the eight of at least one of those rollers, e.g., along directions 1412a and 1412b, or directions opposite thereto, to adjust the gap between these rollers, and / or to adjust the pressure applied to any target starting material disposed between the two rollers. The height adjustment structures (e.g., 1402a and 1402b) may enable manual and / or automaticadjustment of the vertical position of at least one roller in order to adjust the gap between the two rollers. Actuator 1401 is operatively coupled with supportive roller 1411 , e.g., to enable rotating the supporting roller with respect to the die roller. The die roller may have a dedicated actuator to control its rotation. The die roller may use actuator in 1402a and / or 1202b to control rolling of the die roller. The framing 1413 may be affixed to a stage such as stage 1301 of Fig. 13. While rotation of the rollers in Fig. 14 is electronic (e.g., using actuators such as servo motors), the rotation of the roller(s) may be at least partially manual. In the example show in Fig. 14, the diameters of the die roller and the supporting roller are (e.g., substantially the same, and the lateral length of the portion destined to contact the target starting material, is (e.g., substantially) the same.

[0177] FIG. 15 is another perspective view of the rotary dicer, similar to that of FIG. 14, wherein the two rollers, are vertically stacked. Each roller is coupled to a structural framework and comprises an axel 1501a and 1501b. in this example, the die roller is missing for didactive purposes, while the supporting roller 1511 is in place. The framing comprises portions including bridge 1513, two opposing side couplers such as side coupler 1513b, two opposing sides such as side 1513c that can each couple to a stage (not shown) at its bottom portions such as 1513d. The rotary dicer has a front side and an opposing back side. The front side is open such that a user can reach the die roller and exchange the die, e.g., from location 1514.

[0178] Fig. 16 shows a side view example of portions of the rotary dicer, related components, and mode of operation. Example 1600 shows a rotary dicer having a top roller 1603 vertically stacked above a bottom roller 1602, relative to gravitational vector 1690 pointing towards the gravitational center G of the ambient environment (e.g., Earth). If the top roller is the die roller, the bottom roller is the supportive roller. If the top roller is the supportive roller, the bottom roller is the die roller. While the die roller is shown as stacked above the supporting roller, the die roller may be located below the supporting roller with respect to vector gravitational vector 1690. In this embodiment, the lower roller 1602 is coupled to a device 1601 that may enable rotation of the roller and / or control of such rotation. The device 1601 may enable high alteration of the bottom roller. Device 1601 is operatively coupled with actuator 1604 (e.g., a motor). Rollers 1602 and 1603. Top roller 1603 is coupled with actuator 1605, e.g., to actuate rotation of top roller 1603. Rollers 1602 and 1603 are held by framing including bridge 1606 and opposing sides 1607a and 1607b. sides 1607a and 1607b are held together by supportive structures such as 1608a and 1608b. There may be four supportive structures coupling the sides 1607a and 1607b, e.g., two supporting structures 1608a and 1608b, and two supporting structures at the back similar to 1608a and 1608b. Each of the roller is accessible from the front and from the back, e.g., to allow replacement of the roller and / or any relief structure (e.g., die) coupled with theroller, e.g., depending at least in part on the design to be cut, and / or sharpness of a relief portion (e.g., knifes). Broken lined arrow 1610 shows an optional direction from which the die can be reached by a user. The user may be animate or inanimate, e.g., a robot or a human.

[0179] Example 1630 shows a target starting material processed by two rollers such as the die roller and the supporting roller, coupled with a detection system configured to measure a width of a gap between the rollers. Example 1630 is shown with respect to gravitational vector 1690. The detection system includes a light generator 1634a - an emitter that shines light in a direction. The light is directed to shine into the gap between rollers 1632 and 1633. Light emerging out of the gap, is detected by sensor 1634b - the light receiver. The detection system can detect the gap at varied precisions, e.g., optically. For a distance between the emitter and receiver depicted in 1650, one can measure the gap with respective precision listed in 1651. For example, at a receiver - emitter distance of about 20 millimeters, the gap can be detected in a precision of about 1 micrometer. For example, at a receiver - emitter distance of about 100 millimeters, the gap can be detected in a precision of about 2.5 micrometer. For example, at a receiver - emitter distance of about 500 millimeters, the gap can be detected in a precision of about 5 micrometers. The longer the distance between the emitter and receivers, the less accurate is the gap measurement. The target starting material can be pulled laterally 1631b into the gap between rollers 1632 and 1633, and be expelled vertically 1631a. The target starting material can be pulled vertically 1631a into the gap between rollers 1632 and 1633, and be expelled laterally 1631b. The rollers may be any two rollers of the rotary dicer, e.g., the die roller and the supporting roller.

[0180] In some embodiments, the rotary dicer comprises a supporting roller and a die roller. Both rollers may be operatively coupled through a system, as depicted, such that when one roller rotates in one direction and speed, the second roller, via the system rotates at an equivalent speed in a direction opposite to that of the internal roller. In some embodiments, the system is a gear system. As depicted, the rotary dicer may receive sheet material under tension to perform the cutting and potential calender functions described herein.

[0181] Fig. 17 depicts a (e.g., flexible) relief containing sheet or “die” 1710 depicted in an open sheet form comprising a die subunit 1701 for a cutting, an exploded view 1720 of a die subunit such as 1701. Die sheet 1710 is converted 1760 a warped form 1730, such that the endpoints of each die are in contact, e.g., to couple with an internal roller of the die roller. Die 1710 is patterned with cutting edges such as edge 1705, to produce cutting edges of a relief design (e.g., knives). The die 1710 and the cutting edges 1705 may be fabricated utilizing the mask-etching techniques such as disclosed herein, e.g., photolithography. The cutting edges may be further processed, e.g., to sharpen or round out the cutting edge 1705 such as round out angled structures, e.g., normal angles or acute angels. In some embodiments, the cutting edge 1705 may be sharpened with a laser processing technique.In some embodiments, the cutting edges 1705 may be rounded in order to lessen adhesion during the cutting process. The die may be generally designed to lessen adhesion of the target starting material and / or of the resulting cuttings and remainder material, during the cutting process, e.g., depending on the target starting material. The die 1701 is designed to cut an electrode having current collector and active material coupled thereto. Die subunit 1701 comprises dies of aligning structures 1701a and 1701b. The alignment structures may be configured to enable the alignment of the cuttings with respect to each other and / or to another component of the resulting device, e.g., stacked cells. The die comprises sections for tabs 1704a and 1704b disposed at distal edges of the die portion 1703 designated to cut active material of the electrode in a central region of the die. Die sheet 1701 is rectangular, having a long side 1761 (length) and a short side 1762 (width). The die roller includes a portion configured to accept the die sheet, which portion is a central portion. The long side of the die sheet is (e.g., substantially) equal to a perimeter of a side of the die roller portion configure to accept the die sheet. The short side of the die sheet is (e.g., substantially) equal to lateral length of the die roller portion configure to accept the die sheet.

[0182] Fig. 18 depicts an example of a standalone roller such as a die roller, comprising a roller, and an axel designed to couple to a framing, actuation system, and / or control system such as disclosed herein. The roller may comprise a material suitable for the structure of the rotary dicer such as described herein. In some embodiments, the roller comprises an elemental metal, a metal alloy, or any material disclosed herein. The roller may comprise a material configured to allow the roller to serve its intended purpose in the rotary dicer. The metal alloy may comprise stainless steel or Inconel. The roller depicted in Fig. 18 may be a die roller. The roller has an axel showing side 1803 thereof, a central portion 1801 configured to accept the die sheet, and side portions 1802a and 1802b bordering distal sections of the central portion. A gear 1804 is coupled with the die roller. The die roller comprising two concentric cylinders, e.g., the first comprising axel 1803, and the second comprising portion 1801. The die may be wrapped around the external surface of the roller, and may be kept flush with the surface of the roller by any techniques disclosed herein, e.g., an adhesive substance (e.g., epoxy), fasteners (e.g., screws), an attractive force (e.g., magnetic), or any combination thereof.

[0183] FIG. 19 depicts a photograph of a rotary dicer fitted with a cutting die 1940 around the die roller, the die roller being located above supporting roller 1932. Both rollers are coupled with a framing that includes bridge 1934, two opposing sides such as side 1933, supporting structures such as 1931. The rotary dicer sits on a tabletop, The rotary dicer comprises gear systems such as gears 1936 and 1934 that each operatively coupled to a respective roller. The supporting roller is coupled with gear system 1934 and electronic actuation system portion 1934. Supportive roller 1932 is also coupled with a manual rotationsystem having handle 1939, e.g., for operation, safety, and / or maintenance purposes. Die roller 1940 is coupled with gear system 1936 and actuator 1938. The rollers can be compressed with respect to each other when the target starting material is disposed between them. The rollers can be separated from each other by a gap. The separation can be using a manual and / or electronic device. The separation may utilize one or more lead screws. Fig. 19 shows an example of a rotary dicer having a gap separated by lead screws such as lead screw 1941. In the example of Fig. 19, the die roller is coupled with die having lateral length of 105 millimeters. Fig. 19 is shown in accordance with the scale bar

[0184] In some embodiments, the rotary dicer is coupled with a die sheet / foil. The die sheet may have a width configured to couple with a lateral length of the die accepting portion of the die roller. The lateral length of the accepting portion may be at least about at least 5 mm, 10mm, 50mm, 100mm, 150mm, or 200mm. The lateral length of the accepting portion may be at most about 10mm, 50mm, 100mm, 150mm, 200mm, 500mm, or 1000mm. The lateral length of the accepting portion may be any value between the aforementioned values, e.g., from about 5mm to about 1000mm, or from about 50mm to about 150mm. The lateral length of the accepting portion of the die roller may be (e.g., substantially) equal to the width of the die sheet.

[0185] The circumference of the cylinder of the accepting portion may be at least about 50mm, 100mm, 250mm, 500mm, 600mm, 800mm, 1000mm, 1500mm, or 2000mm. The circumference of the cylinder of the accepting portion may be at most about 100mm, 250mm, 500mm, 600mm, 800mm, 1000mm, 1500mm, 2000mm, or 3000mm. The circumference of the cylinder of the accepting portion may be between any of the aforementioned values, e.g., from about 100mm to about 3000mm, or from about 400mm to about 800mm. The circumference of the accepting portion of the die roller may be (e.g., substantially) equal to the length of the die sheet.

[0186] Fig. 20 shows an image of the die roller of the rotary dicer having a die 2001 fitted thereon. The die was etched and processed to result in a sharp, patterned relief surface, comprising repeated rectangular units, in accordance with the scale bar. Fig. 20 illustrates the width of each rectangle to be approximately 4.77mm. The die roller is coupled with a framing, showing a support structure 2020. The die includes line structures 2002 to cut (e.g., elongated) cell components including electrodes separators, dividers, and / or end plates, of cells. The die includes engagement structures 2003, e.g., to engage a busbar with the cut cell portion in an engagement structure. The die includes alignment structures 2004, e.g., to align the cell components with respect to each other, e.g., in a cell and / or in a cell stack. With respect to the target starting material, the alignment structures may be cut by the die, or may be debossed by the die. With respect to the target starting material, the engagement structures may be cut by the die, or may be debossed by the die. The debossed structuresmay be processed by other methodologies to generate the (e.g., smaller) cut portion in the generated cuttings.

[0187] In some embodiments, at least one roller of the rotary dicer is rotating upon use. The rotating speed may be at least about 10 rotations per minute (RPM), 20 RPM, 30 RPM, 33RPM, 40 RPM, 47RPM, or 50 RPM. The rotating speed may be at most about 20 RPM, 30 RPM, 33RPM, 40 RPM, 47RPM, 50 RPM or 100 RPM. The rotating speed of the roller may be between the aforementioned values, e.g., from about 10 RPM to about 100 RPM< or from about 20 RPM to about 50 RPM. The rotary dicer is configured to process the target starting material at a speed. The speed may be at least about 5 meters per minute (m / min), 10 m / min, 15 m / min, 20 m / min, 25 m / min, 30 m / min, or 50 m / min. The speed may be at most about 10 m / min, 15 m / min, 20 m / min, 25 m / min, 30 m / min, 50 m / min, or 55m / min. The speed may be of any velocity value between the aforementioned values, e.g., from about 5 m / min to about 55 m / min, or from about 10 m / min to about 25 m / min.

[0188] Fig. 21 shows an example photograph of processed die portions by a rotary dicer, in accordance with processes herein. The die was fitted on a die roller having a diameter of about 143mm. The die is visibly etched, comprising light etching patterns indicative of the blades utilized to penetrate and cut through target starting material destined to pass through the rotary dicer. The die depicted in Fig. 21 successfully cut cathode and anode battery components at roller speeds ranging from up to about 33 rounds per minute (RPM). The die successfully cut cathode and anode battery components at speeds of 15 meters of target starting material (e.g., sheet of material) per minute (m / min). The die produced cathode components comprising an LCO-based active material layer on an aluminum sheet current collector. Anode components produced by the die comprised either a Si-C composite or an SiOxactive material layer, each deposited on a separate copper sheet current collector, respectively. In some embodiments of a die disclosed herein, like the die of Fig. 21, the die of the rotary dicer may operate on separator sheet material. In an example, the (e.g., anode) active material comprises SiOx and Si-C. In Fig. 21, the die portions are configured to (a) cut / deboss an alignment structure or an engagement structure; (b) cut / deboss a tab portion (e.g., of a current collector); (c) cut / deboss an active material portion of the target starting material. Engagement or alignment structures related dies are designated by numerals 2101 and 2105. A tab die structure is shown in 2102. An active material portion die is shown in 2103. A portion devoid of a tab die is shown in 2104, e.g., which can cut material to generate a separator, or can process a target starting material that comprises an active material portion of an electrode deposited on a charge carrier. The die may comprise a tab portion die on one of its distal sides (e.g., Fig. 17, 1704a and 1704a), on one of its distal sides, or on none of its distal sides.

[0189] Photographs 19-21 constitute examples of rotary dicers and their respective dies.

[0190] In some embodiments, the rotary dicer is configured to cut and / or deboss (e.g., compress or indent) the target starting material. The die may be configured to cut at an area parallel to the longitudinal axis of the die roller and of the supporting roller, the area including the compressed area of the target starting material by the die roller and by the supporting roller. Such processing area may be smaller than an area required to cut the entire design to be cut, e.g., as is the case in press cutting. Arrangement of the shapes to be cut in the die may be configured to minimize the force required to cut and / or embossed the requested shape. The force required to cut and / or emboss the requested shape may be adjusted dynamically, e.g., depending on the extent of the shape to be cut when a subject portion of the die engages with the target starting material. The dynamic adjustment may be performed at least in part automatically, e.g., using the controller. The dynamic adjustment may be premade, e.g., using open loop control. The dynamic adjustment may be made at least in part by considering (a) one or more material properties of the subject material to be cut, (b) rotational speed of the die, (c) complexity of the design (e.g., sharp angles and / or size of portions to be cut), (d) one or more properties of the die (e.g., material, edge sharpness, knife angles with respect to the plane, e.g., Fig. 17), (e) gap between the die roller and the supporting roller, or (f) any combination thereof. The dynamic adjustment may comprise using physics simulations, e.g., comprising considering forces, dynamics, and / or material makeup. The control system may be configured to control calendering of the target starting material, e.g., the control system may set a height and force the target starting material to be at a requested resulting height. The control system may be configured to maintain a height of the target starting material, e.g., configured to maintain a height of the active material on a current collector for us as an electrode. The control system may be configured to control a pressure, e.g., maintain pressure regardless of the resulting height. The control system (e.g., during the calendering) may be devoid of pressure control. The control system (e.g., during the dicing) may include pressure control. The control system may control one or more attributes at least in part on the action of the components (e.g., device) it controls.

[0191] In some embodiments, the electrode is separated from a counter electrode by a gap. The gap may comprise a separator. The separator may comprise a polymer, a resin, or a ceramic. The ceramic may comprise alumina (AI2O3), zirconia (ZnC>2), magnesium oxide (MgO), boron nitride (BN), mullite, boehmite, or silicon carbide (SiC, e.g., in pure form), boehmite (AIO(OH)), or any combination thereof. The separator may comprise a central layer of polymer and / or resin, the central layer may be coupled at its two opposing sides by a mass of the ceramic. The ceramic mass may be in a layer form. The ceramic mass may comprise a binder such as disclosed herein.

[0192] In some embodiments, the die is configured to cut one or more components of a cell. A die may be configured to cut at least two different components of the cell such as anodeand cathode, e.g., in separate cutting sessions. A die may be configured to cut one type of component of a cell such as electrode and separator, e.g., and not other components of the cell.

[0193] Fig. 22 shows an example of a process flow to produce multiple battery components by utilizing a rotary dicer such as disclosed herein. In one embodiment, three separate rotary dicers, each comprising a die, each die etched with a custom pattern, produce three separate battery components via the functionality disclosed herein. For example, at 2202, a first rotary dicer assembled with a first die which has been processed with a pattern meant to produce cathode structure components of an electrode assembly, is fed cathode structure sheet material in roll-to-roll format. The cathode structure battery components are produced and saved for later electrode assembly. In this example, at 2203, a second rotary dicer assembled with a second die which has been processed with a pattern meant to produce anode structure components of an electrode assembly, is fed anode structure sheet material in roll-to-roll format. The anode structure battery components are produced and saved for later electrode assembly. Lastly in this example, at 2204, a third rotary dicer assembled with a third die which has been processed with a pattern meant to produce separator structure components of an electrode assembly, is fed separator structure sheet material in roll-to-roll format. The separator structure battery components are produced and delivered with the formerly produced cathode and anode structure components to any downstream processes that assembly the three components into an electrode assembly. Implementations of this technique would allow each of the three rotary dies to operate in separate environments suitable for production of their respective battery component. For example, two rotary dicers, each dedicated to production of cathode and anode structures, respectively, may operate in controlled dry room environments to minimize moisture exposure to sensitive pre-dried active materials on the surface of the cathode and anode structures, while a third rotary dicer dedicated to production of separator structures may operate outside of a dry room environment. Such processing plan decisions are subject to the judgement of the manufacturer.

[0194] In another implementation, a singular rotary dicer may be used three times, each time with a different die, in order to produce three different battery components. For example, at start 2201 , the rotary dicer may be fitted with a die dedicated to production of cathode structure components. At 2202, the rotary dicer with said die may produce the cathode structure components. The production may halt, the cathode structures may be collected, the die may change to a die dedicated to produce anode structure components, the rotary dicer may receive anode structure sheet material in roll-to-roll format, and resume operation. At 2203, the rotary dicer, now fitted with a die for anode structure component production and now receiving anode structure sheet material, may produce anode structurecomponents. The production may then halt, the anode structures may be collected, the die may then change to a die dedicated to produce separator structure components, the rotary dicer may then receive anode structure sheet material in roll-to-roll format, and finally resume operation. At 2204, the rotary dicer, now fitted with a die for separator structure component production and now receiving separator structure sheet material, may produce separator structure components. The rotary dicer may lastly cease operation at 2205, and the separator structures may be collected. In this implementation, the rotary dicer may operate in the same environment and location to produce varying battery components.

[0195] As illustrated in Figs. 12, 17, 18, 21 and 22, and discussed herein (e.g., above), systems and methods are disclosed herein employing rotary die cutting technologies, e.g., for mechanical dicing of secondary battery electrodes in order to at least partially replace laser dicing of secondary battery electrodes. The systems and methods disclosed herein allow for faster, more precise, and / or cleaner dicing, e.g., while allow for roll-to-roll continuous processing of (e.g., secondary) battery electrodes. The dicing process is fundamental to the manufacturing process of (e.g., secondary) batteries as it is responsible for the definition of individual electrodes, from R2R (roll-to-roll) coated electrode material. Rotary die cutting is utilized, e.g., in the conversion industry, where it is primarily used to create custom parts from a variety of roll stock. A challenge for adopting this technique in the battery industry is the target starting material, e.g., including particulate material, e.g., that can be loosely bound. The bound particulate material may be such that it withstands the cutting (e.g., by the rotary dicer) without (e.g., substantial) harm to the active material. The substantial harm relates to a measurable harm that would cause the active material to not perform according to its requested and / or designed specification in the final product for which it is designed. The materials that can be cut using rotary dicing can range from soft metals, to plastics, adhesives and / or paper. The thicknesses range from tens of microns to millimeters. A schematic of an examle rotary die assembly is shown in Fig. 12.

[0196] In some embodiments, the die (the part of the assembly that does the cutting) is fabricated from a ferrous metal and is flexible, e.g., due to its thickness. The cutting features are first defined by etching (e.g., for accuracy) and then machined in a secondary process to fully define the cutting edges. An example rotary die and magnetic rotary chuck are shown in FIGS. 17 and 18, respectively. By feeding raw material (in roll form) between the die assembly and a supportive roller (e.g., an anvil), the material is pressed against the cutting edge of the die and cleaved as it moves therethrough, e.g., linearly. The rotary shape of the die allows a cutting edge to always be present for the work to interact with. This is unlike a press system which requires both the actuation of the work, in a lateral direction, and the press in a vertical direction. An example die portions are shown on Fig. 21. The die can be used to produce the cathode, anode, and / or separator components of a secondary battery.

[0197] In one aspect, the systems and methods disclosed herein include a process for manufacturing electrodes of a (e.g., secondary) battery using a rotary die assembly. As shown in Fig. 22, the process begins by producing, using a first die of the rotary die assembly, a cathode component of an electrode assembly of the secondary battery. The process continues by producing, using a second die of the rotary die assembly, an anode component of the electrode assembly of the secondary battery. The process finished by producing, using a third die of the rotary die assembly, a separator component of the electrode assembly of the secondary battery.

[0198] In another aspect, the systems and methods disclosed herein include a rotary die assembly for manufacturing electrodes of a secondary battery. The rotary die assembly includes a first die, a second die, and a third die. The rotary die assembly is configured to produce, using the first die of the rotary die assembly, a cathode component of an electrode assembly of the secondary battery. The rotary die assembly is also configured to produce, using the second die of the rotary die assembly, an anode component of the electrode assembly of the secondary battery. The rotary die assembly is also configured to produce, using the third die of the rotary die assembly, a separator component of the electrode assembly of the secondary battery.

[0199] The systems and methods discussed herein can allow for faster processing of electrode components, e.g., as compared to laser dicing. The systems and methods discussed herein allow for the ability to gang cutters - allowing for more than one cut width of electrode at once. The systems and methods discussed herein allow for reduced occurrence (e.g., no) heat effected zone (HAZ), minimal to no debris, and / or minimal to no redeposition.

[0200] The systems and methods discussed herein can be modified at least in part by adjusting the size and shape of the die, as well as the cutting height of the die with respect to the electrode material, e.g., allowing for stepped cuts. In addition, the systems and methods discussed herein can be used in a hybrid approach where lasers are used for some electrode components of the processing and not others. The stepped cuts may comprise sequential cuts. The die roller may be configured for sequential cuttings and / or embossing of the target starting material.

[0201] In some embodiments, the system, device, and / or apparatus disclosed herein comprises a control system. The control system may comprise one or more controllers. The control system may comprise, or be operatively coupled with, one or more devices, apparatuses, and / or systems of the mechanism (e.g., system, device, or apparatus) disclosed herein, including any component of the device(s), apparatuses(s), and / or system(s). The controller(s) may comprise, or be operatively coupled with, a hierarchical control system. The hierarchical control system may comprise at least three, four, or five,control levels. In some embodiments, at least two operations are performed, or directed, by the same controller. In some embodiments, at least two operations are each performed, or directed, by a different controller. A control system may comprise a control system. A control system may comprise a laser control system. The controller may comprise a feedback control scheme. The feedback control scheme may comprise an open feedback loop control scheme. The feedback loop control scheme may comprise a closed feedback loop control scheme. The feedback control scheme may comprise hardware compensation. The feedback control scheme may comprise software compensation. The control system may comprise, or be operatively coupled with, a metrological detection system and configured to receive measurement data from the metrological detection system. The control system may be configured to generate control signals responsive to the measurement data collected by the metrological detection system.

[0202] In some embodiments, the systems, apparatuses, devices, and / or components thereof disclosed herein comprise one or more controllers. The one or more controllers can comprise one or more central processing unit (CPU), input / output (I / O) and / or communications module. The CPU can comprise electronic circuitry that carries out instructions of a computer program by performing arithmetic, logical, control and I / O operations specified by the instructions. The controller can comprise a suitable software (e.g., operating system). The control system may optionally include a feedback control loop and / or feed-forward control loop. The controllers may be shared between one or more systems or apparatuses. Each apparatus or system may have its own controller. Two or more systems and / or their components may share a controller. Two or more apparatuses and / or its components may share a controller. The controller may monitor and / or direct (e.g., physical) alteration of the operating conditions of the apparatuses, software, and / or methods described herein. The controller may be a manual or a non-manual controller. The controller may be an automatic controller. The controller may operate upon request. The controller may be a programmable controller. The controller may be programed. The controller may comprise a processing unit (e.g., CPU or GPU). The controller may receive an input (e.g., from a sensor). The controller may deliver an output. The controller may comprise multiple controllers. The controller may receive multiple inputs. The controller may generate multiple outputs. The controller system may comprise a single input single output controller (SISO) or a multiple input multiple output controller (MIMO). The controller may interpret the input signal received. The controller may acquire data from one or more sensors. Acquiring may comprise receive or extract. The data may comprise measurement, estimation, determination, generation, or any combination thereof. The controller may comprise feedback control. The controller may comprise feed-forward control. The control may comprise on-off control, proportional control, proportional-integral (PI) control, orproportional-integral-derivative (PID) control. The control may comprise open loop control, or closed loop control. The controller may comprise closed loop control. The controller may comprise open loop control. The controller may comprise a user interface. The user interface may comprise a keyboard, keypad, mouse, touch screen, microphone, speech recognition package, camera, imaging system, or any combination thereof. The outputs may include a display (e.g., screen), speaker, or printer.

[0203] Fig. 23 shows a schematic example of process 2320 controlled using a control system in a feedback loop control scheme, e.g., in a closed loop control scheme. The control system receives set point 2305 to comparator 2306 that generates an error signal, which is fed 2345 into controller 2340. In other control systems, the comparator can be part of the controller. Controller 2340 generates a control signal that is fed into controlling element 2330. The controlling element may comprise a mechanism utilized for its control function to control process 2320. Controlling element 2330 provides an input to process 2320. The mechanism may effectuate a physical and / or a chemical change, which change is the input to process 2320. The physical change may comprise mechanical change, magnetic change, electromagnetic change, piezoelectric change, electrical change, pressure change, or temperature change. The chemical change may comprise a change in a chemical gradient, or in a chemical entity. Process 2320 can be any process disclosed herein, e.g., any method such as a fabrication (e.g., manufacturing) method. Process 2320 generates an output detected by measuring element 2310, e.g., using its sensor(s). The output provided by process 2320 may be a reaction of the process to the input provided by control element 2330. Measuring element 2310 generates a variable amplitude signal that is fed back into comparator 2306 and is again compared with the setpoint. Measuring element 2310 optionally also generates a controlled variable 2381. Control element 2330 optionally also receives a manipulated variable 2382, e.g., from an external source such as a processor and / or a communication system. Sensor(s) can be used by measuring element 2310 for the measurement of parameters of the process, e.g., 2320. The sensor measurement can be a determination of an amplitude of a parameter such as of a material, e.g., as disclosed herein. In an example, the value of the measurement is consistent and repeatable. The sensor(s) can convert the physical parameters (e.g., repeatedly, and reliably) into a usable form by the control system, e.g., into an electrical signal such as in a digital form. The comparator can perform an error detection, e.g., by determining a difference between the amplitude of the measured variable and a requested set reference point (e.g., set point 2305), which difference is the error signal. The error signal can be amplified and / or conditioned such as filtered. The signal amplification and / or conditioning may be performed by an external component to the controller (e.g., 2340), or within the controller. The reference point (e.g., set point) can be stored in the memory of the controller, or of a memoryoperatively coupled with the controller. The controller can be a (e.g., micro-) processorbased system that can determine the next operation to be taken in a process. The process may be sequential. The controller may evaluate the error signal in a continuous process control system, e.g., to determine what action is to be taken. The controller (e.g., 2340) can condition the signal, or be operatively coupled with a unit conditioning the system. Conditioning the signal may comprise noise filtering. Conditioning the signal may comprise correcting the signal for a non-linearity in the sensor. The controller may include the parameters of the process input control element. The controller may condition the error signal to direct the control element, e.g., 2330. The controller can monitor input signal(s). The input signals may be interrelated. The controller may be configured to direct at least two control elements in concert. The controller may be configured to direct at least two control elements simultaneously. The controller may be configured to direct at least two control elements sequentially. The control element (e.g., 2330) can be a device that controls an incoming material to the process, or any other attribute of the process comprising a physical attribute or a chemical attribute. The physical attribute may comprise mechanical, magnetic, piezoelectric, electromagnetic, electrical, pressure, or temperature attribute. The chemical attribute may comprise a chemical gradient, or in a chemical entity. The control element can be a flow control element. The control element can be a temperature control element. The control element can have toggle (e.g., On / Off) characteristics. The control element can provide linear, or non-linear, control of the control element. The control element can be used to adjust the input to the process, e.g., bringing the output variable to the value of the set point. The measuring element (e.g., 2310) can consist of sensor(s) to measure the physical property of a variable, a transducer to convert the sensor signal into an electrical signal, and / or a transmitter to amplify the electrical signal. The amplification of the signal can be transmitted with minimal (e.g., without measurable) loss. The control element may comprise an actuator which changes the electrical signal from the controller into a signal to operate and / or control a physical device such as a valve. The controller may comprise a memory or be operatively coupled with a memory. The control system may comprise a summing circuit, e.g., to compare the set point to the sensed signal, so that it can generate the error signal. The summing circuit may be part of the comparator. The controller may use the error signal to generate a correctional signal to control the control element. In an example, the controller controls a valve via an actuator and the input variable. The sensors of the measuring element may comprise optical sensors, temperature sensors, pressure sensors, chemical sensors, proximity sensors, viscosity sensors, chemical sensors, or any other sensor disclosed herein. The chemical sensors may sense a material comprising oxygen, water, or any other reactive agent(s) herein. The sensors may be configured to sense one or more attributes of the methods disclosed herein such as the fabrication methods.

[0204] Control may comprise regulate, modulate, adjust, maintain, alter, change, govern, manage, restrain, restrict, direct, guide, oversee, manage, preserve, sustain, restrain, temper, or vary.

[0205] In some embodiments, the device, system, and / or apparatus disclosed herein comprises a processor. The processor may be a processing unit. The controller may comprise a processing unit. The processing unit may be central. The processing unit may comprise a central processing unit (herein “CPU”). The controllers or control mechanisms (e.g., comprising a computer system) may be programmed to implement methods of the disclosure. The processor may be programmed to implement methods of the disclosure. The controller may control at least one component of the systems and / or apparatuses disclosed herein. Fig. 24 shows a schematic example of a computer system 2400 that is programmed or otherwise configured to facilitate execution any of the methods provided herein.The computer system 2400 can control (e.g., direct, monitor, and / or regulate) various features of the methods, apparatuses, devices, and / or systems of the present disclosure. The computer system 2400 can be part of, or be in communication with, the device, system and / or apparatus disclosed herein. The computer may be coupled with one or more mechanisms disclosed herein, and / or any parts thereof. The computer system 2400 can include a processing unit 2406 (also “processor,” “computer” and “computer processor” used herein). The computer system may include memory or memory location 2402 (e.g., randomaccess memory, read-only memory, flash memory), electronic storage unit 2404 (e.g., hard disk), communication interface 2403 (e.g., network adapter) for communicating with one or more other systems, and peripheral devices 2405, such as cache, other memory, data storage and / or electronic display adapters. The memory 2402, data storage unit 2404, interface 2403, and peripheral devices 2405 are in communication with the processing unit 2406 through a communication bus (solid lines), such as a motherboard. The storage unit can comprise a data storage unit (or data repository) for storing data. The computer system can be operatively coupled with a computer network (“network”) 2401, e.g., with the aid of the communication interface. The network can be the Internet, an internet and / or extranet, or an intranet and / or extranet that is in communication with the Internet. In some cases, the network is a telecommunication and / or data network. The network can include one or more computer servers, which can enable distributed computing, such as cloud computing. The network, in some cases with the aid of the computer system, can implement a peer-to-peer network, which may enable devices coupled with the computer system to behave as a client or a server. The processing unit can execute a sequence of machine- readable instructions, which can be embodied in a program or software. The instructions may be stored in a memory location, e.g., memory 2402. The instructions can be directed to the processing unit, which can subsequently program or otherwise configure the processingunit to implement methods of the present disclosure. Examples of operations performed by the processing unit can include fetch, decode, execute, and write back. The processing unit may interpret and / or execute instructions. The processing unit 2406 may include a microprocessor, a data processor, a central processing unit (CPU), a graphical processing unit (GPU), a system-on-chip (SOC), a co-processor, a network processor, an application specific integrated circuit (ASIC), an application specific instruction-set processor (ASIPs), a controller, a programmable logic device (PLD), a chipset, a field programmable gate array (FPGA), or any combination thereof. The processing unit 2406 can be part of a circuit, such as an integrated circuit. One or more other components of the system (e.g., 2400) can be included in the circuit.

[0206] In some embodiments, the storage unit (e.g., 2404) stores files, such as drivers, libraries, and saved programs. The storage unit can store user data (e.g., user preferences and user programs). In some cases, the computer system can include one or more additional data storage units that are external to the computer system, such as located on a remote server that is in communication with the computer system through an intranet or the Internet. The processor may be configured to process control protocols, e.g., communicate with one or more components of the mechanism (e.g., device, apparatus, and / or system) disclosed herein using the control protocols. Control protocols can be one or more of the internet protocol suites, e.g., transmission control protocol (TCP) or transmission control protocol / internet protocol (TCP / IP). Control protocols can be one or more serial communication protocols. Control protocols can be one or more of controller area networks or another message-based protocol, e.g., for communication with microcontrollers and devices. Control protocols can interface with one or more serial bus interfaces for communication with the mechanism disclosed herein, e.g., with any of its components. The control protocol can be any control protocol disclosed herein.

[0207] In some embodiments, the system, device, and / or apparatus disclosed herein comprises communicating through a network. The computer system can communicate with one or more remote computer systems through a network. For instance, the computer system can communicate with a remote computer system of a user (e.g., operator). Examples of remote computer systems include personal computers (e.g., portable PC), slate or tablet PC's (e.g., Apple® iPad, Samsung® Galaxy Tab), telephones, Smart phones (e.g., Apple® iPhone, Android-enabled device, Blackberry®), or personal digital assistants. A user (e.g., client) can access the computer system via the network.

[0208] In some embodiments, the computer system utilizes program instructions to execute, or direct execution of, operation(s). The program instructions can be inscribed in a machine executable code. Methods described herein can be implemented by way of machine (e.g., computer processor) executable code stored on an electronic storage location of thecomputer system, such as, for example, on the memory 2402 or electronic (e.g., data) storage unit 2404. The machine executable or machine-readable code can be provided in the form of software. During use, the processor (e.g., 2406) can execute the code. In some cases, the code can be retrieved from the storage unit and stored on the memory for ready access by the processor. In some situations, the electronic storage unit can be precluded, and machine-executable instructions are stored on memory. The code can be pre-compiled and configured for use with a machine that has a processer adapted to execute the code or can be compiled during runtime. The code can be supplied in a programming language that can be selected to enable the code to execute in a pre-compiled or as-compiled fashion.

[0209] In some embodiments, the computer system utilizes a machine-readable medium / media to execute, or direct execution of, operation(s). The program instructions can be inscribed in a machine executable code. A machine-readable medium / media, such as computer-executable code, may take many forms, including but not limited to, a tangible storage medium / media, a carrier wave medium, or physical transmission medium. Nonvolatile storage media / medium include, for example, optical or magnetic disks, such as any of the processor related storage devices in any computer(s) or the like, such as may be used to implement the databases. Volatile storage media / medium can include dynamic memory, such as main memory of such a computer platform. Tangible transmission media can include coaxial cables, wire (e.g., copper wire), and / or fiber optics, including the wires that comprise a bus within a computer system. Carrier-wave transmission media may take the form of electric or electromagnetic signals, or acoustic or light waves such as those generated during radio frequency (RF) and infrared (IR) data communications. Common forms of computer-readable media therefore include for example: a floppy disk, a flexible disk, hard disk, magnetic tape, any other magnetic medium, a CD-ROM, DVD or DVD-ROM, any other optical medium, punch cards paper tape, any other physical storage medium / media with patterns of holes, a RAM, a ROM, a PROM and EPROM, a FLASH- EPROM, any other memory chip or cartridge, a carrier wave transporting data or instructions, cables or links transporting such a carrier wave, any other medium from which a computer may read programming code and / or data, or any combination thereof. The memory and / or data storage may comprise a storing device external to and / or removable from device, such as a Universal Serial Bus (USB) memory stick, and / or a hard disk. Many of these forms of computer readable media may be involved in carrying one or more sequences of one or more instructions to a processor for execution.

[0210] In some embodiments, the device, system, and / or apparatus disclosed herein comprises, or is operatively coupled with, a communication technology, e.g., in addition to the optical fiber disclosed herein. The communication may comprise wired or wireless communication. For example, the systems, apparatuses, and / or parts thereof may compriseBluetooth, wi-fi, global positioning system (GPS), or radiofrequency (RF) technology. The RF technology may comprise ultrawideband (UWB) technology. Systems, apparatuses, and / or parts thereof may comprise a communication port. The communication port may be a serial port or a parallel port. The communication port may be a Universal Serial Bus port (i.e. , USB). The systems, apparatuses, and / or parts thereof may comprise USB ports. The USB can be micro- or mini-USB. The surface identification mechanism may comprise a plug and / or a socket, e.g., electrical, AC power, DC power. The systems, apparatuses, and / or parts thereof may comprise an electrical adapter (e.g., AC and / or DC power adapter). The systems, apparatuses, and / or parts thereof may comprise a power connector. The power connector can be an electrical power connector. The power connector may comprise a magnetically attached power connector. The power connector can be a dock connector. The connector can be a data and power connector. The connector may comprise pins. The connector may comprise at least about 10, 15, 18, 20, 22, 24, 26, 28, 30, 40, 42, 45, 50, 55, 80, or 100 pins.

[0211] In some embodiments, the energy manipulation device (e.g., battery) is utilized for providing energy to electrical devices. The energy manipulation device(s) may include smartphone, tablet, wearable electronics (watches, glasses, health tracks), power bank (e.g., for mobile devices), micro portable devices (drones, cameras, smart card), mobile Wi-Fi, Bluetooth headset, smart home related device (loTs), electric toothbrushes, precision grooming tools, small-scale gardening equipment, (e.g., service) robots, (e.g., compact) medical such as chest compression, cosmetics, (e.g., compact) exercise, other wellness devices, learning tools, UAVs (drones) such as for short distance, e.g., racing, short distance, and military drones, torpedoes, and missiles. Also Helicopter, and other industrial equipment, online baking tools (e.g., a bank Ukey), Bluetooth enable devices, EVs (e.g., including consumer, bikes, race cars, scooters), body worn vests, warmers, coolers, cameras, Internet of Things (loTs), Wearables, watches, e-cigarette, augmented reality (AR) glasses, virtual reality (VR) glasses, sensors, hearing devices, smart glasses, or any combination thereof. The energy manipulation device may be utilized for any battery powered electronic product. The robots may be service-robots for cargo, e.g., maneuvering. The cargo maneuvering may be within a facility, or between facilities. The robot may comprise a warehouse robot. The EV cargo UAV. The EV may comprise a UAV. The energy manipulation device may be utilized for control. The energy manipulation device may be utilized for video streaming, e.g., MP3 player. The drone may be an underwater drone and / or an aerial drone.

[0212] In some embodiments, the energy manipulation device is manufactured. The energy manipulation device can be fabricated (e.g., fabricated). The environment may or may not be an ambient environment. The environment may comprise one or more environmentalcharacteristics different than those of the ambient environment. The one or more characteristics may comprise a lower concentration of reactive agent, a higher temperature, or a higher pressure. The reactive agent may react with one or more components of the energy manipulation device, e.g., during its use, storage, shipping, maintenance, and / or fabrication. The cells may be fabricated according to any configuration disclosed herein, and using any material disclosed herein, as appropriate. The tabs may be folded, welded, adhered to a tacky connector, and / or adhered to a solid busbar. The manufacture process (e.g., of any component disclosed herein) may comprise printing, stenciling, heat application, heat transfer, any combination thereof, or any plurality thereof, as applicable. The application may comprise deposition. The printing may comprise stencil printing, direct printing, or sublimation printing. One or more operations of the manufacturing may be controlled by a control system, e.g., comprising at least one controller such as any control system disclosed herein. The calendering may comprise temperature conditioning, e.g., heating. The operation of the rotary dicer may comprise temperature conditioning, e.g., as disclosed herein. One or more manufacturing conditions may require temperature conditioning, e.g., using any of the temperature conditioning systems disclosed herein, as applicable. The control system may be configured to automatically control the temperature during the temperature conditioning. The temperature conditioning may be manually and / or automatically controlled, e.g., using a control system such as disclosed herein.

[0213] In some embodiments, the cells are manufactured, e.g., to form a battery. An insulator and / or adhesive (e.g., tacky material) may be applied such as at a glass or at a melting temperature of at least one component of the adhesive, e.g., at a temperature of at least about 100°C, 150°C, 200°C, or 250°C. The application of the adhesive and / or insulator can be at least at ambient pressure, or above ambient pressure, e.g., at a pressure of at least about 14.5psi, 14.7psi, 20 psi, or 25psi. The adhesive and / or insulator may harden. The adhesive and / or insulator may have a thickness of at least about 50 pm, 100 pm, or 150 microns (pm). The adhesive and / or insulator may have a resistance, e.g., of at most about 0.1 milliohms (mfi), 0.2 mQ, 0.5 mfi, 1 mfi, or 2 ohms (Q).

[0214] The processes discussed above are intended to be illustrative and not limiting. One skilled in the art would appreciate that the operations (e.g., steps) of the processes discussed herein may be omitted, modified, combined, and / or rearranged, and any additional operations (e.g., steps) may be performed without departing from the scope of the invention. More generally, the above disclosure is meant to be examples and not limiting. Furthermore, it should be noted that the features and limitations described in any one embodiment may be applied to any other embodiment herein, and flowcharts or examples relating to one embodiment may be combined with any other embodiment in a suitable manner, done in different orders, or done in parallel. In addition, the systems and methodsdescribed herein may be performed in real time. It should also be noted that the systems and / or methods described above may be applied to, or used in accordance with, other systems and / or methods.

[0215] While preferred embodiments of the present inventions have been shown, and described herein, it will be obvious to those skilled in the art that such embodiments are provided by way of example only. It is not intended that the present disclosure be limited by the specific examples provided within the specification. While the present disclosure has been described with reference to the afore-mentioned specification, the descriptions and illustrations of the embodiments herein are not meant to be construed in a limiting sense. Numerous variations, changes, and substitutions will now occur to those skilled in the art without departing from the present disclosure. Furthermore, it shall be understood that all aspects of the present disclosure are not limited to the specific depictions, configurations, or relative proportions set forth herein which depend upon a variety of conditions and variables. It should be understood that various alternatives to the embodiments described herein might be employed in practicing the present disclosure. It is therefore contemplated that the present disclosure shall also cover any such alternatives, modifications, variations, or equivalents. It is intended that the following claims define the scope of the present disclosure and that methods and structures within the scope of these claims and their equivalents be covered thereby.

Claims

CLAIMSWhat is claimed is:

1. A device for processing a target starting material for one or more battery cells, the device comprising: a frame; an internal roller having a first lateral axis, the internal roller being operatively coupled with the frame, the internal roller being configured to operatively couple with a die to generate a die roller, the internal roller being configured to couple with the die such that upon rotation (e.g., revolution) of the internal roller the die remains (e.g., substantially) stationary relative to the internal roller; and a supportive roller having a second lateral axis (e.g., substantially) parallel to the first lateral axis, the supportive roller being separated from the internal roller by a gap, the supportive roller and the internal roller being configured to rotate relative to each other, such that during their rotation (i) the target starting material is pulled into the gap, (ii) the target starting material interacts with die, interaction of the die with the target starting material resulting in a pattern of the die being compressed onto the target starting material to cut, indent, or cut and indent, the target starting material to generate a product according to the pattern of the die, or (iii) any combination of (i) and (ii), the product being components of one or more battery cells, and:(a) the device being configured to process the target starting material that comprises a planar material operatively coupled with a particulate material mass, the planar material comprising a foil or a sheet, without (e.g., substantially) deforming the particulate material mass;(b) the device being configured to dynamically alter the gap;(c) the device being configured to dynamically alter compression of the die onto the target starting material;(d) the die being optimized to reduce variance in a force required to compress the die onto the target starting material, the variance being dependent at least in part on a design layout of the die;(e) the internal roller is configured to operatively couple with a die at least in part by using an attractive force;(f) the device being configured to operate in an enclosure having an internal environment different from an ambient environment external to the enclosure, the product being susceptible to one or more reactive agents present in the ambient environment;(g) at least one component of the device is configured for temperature conditioning;(h) the die comprising at least one coating configured to lessen an occurrence of portions ofthe target starting material adhering to the die after processing of the target starting material;(i) the die and the target starting material including at least one type of material in common; or(j) any combination thereof.

2. The device of claim 1 , wherein the device is configured to process the target starting material that comprises a planar material operatively coupled with the particulate material mass; optionally wherein the particulate material mass is an anode active material, and the planar material is a current collector with which the anode active material is coupled; optionally wherein the anode active material comprises a protective material configured to be cleaned from the product; and optionally wherein the protective material comprising a binder or a coating.

3. The device of claim 1, wherein the device is configured to process the particulate material mass without (e.g., substantially) deforming the particulate material mass; optionally wherein deforming the particulate material mass comprises introducing one or more defects comprising cracks, dislocations, separation of the particulate material from a structure (e.g., sheet / foil) to which it is coupled with, unwanted growth centers, any types thereof, or any combination thereof; and optionally wherein the unwanted growth centers comprise (a) crystallization centers, (b) metallurgical phases, (c) grown centers accumulation of a reduced phase of charge carriers, or (d) any plurality of types thereof, or (e) any combination thereof.

4. The device of claim 1, wherein device is configured to dynamically alter the gap; optionally wherein dynamic alteration of the gap is dependent at least in part on the target starting material, a relative revolution of the die roller relative to the supporting roller, a design of the die, a fidelity requested from the product, or any combination thereof; optionally wherein (I) the higher the fidelity the lower the revolution speed, (II) the greater a fragility of the material, the lower the revolution speed; optionally wherein alteration of the gap is done at least in part using a control system; and optionally wherein alternation of the gap is done using (a) a feedback control scheme, (b) feed forward control scheme, (c) a lookup table, (d) historical measurements, or (e) any combination thereof.

5. The device of claim 1, wherein the device being configured to dynamically alter compression of the die onto the target starting material; optionally wherein dynamic alteration of the compression is dependent at least in part on the target starting material, a relative revolution of the die roller relative to the supporting roller, a design of the die, a fidelity requested from the product, or any combination thereof; optionally wherein (I) the higher the fidelity the lower the revolution speed, (II) the greater a fragility of the material, the lower the revolution speed; optionally wherein alteration of the gap is done at least in part using a control system; and optionally wherein alternation of the gap is done using (a) a feedback control scheme, (b) feed forward control scheme, (c) a lookup table, (d) historicalmeasurements, or (e) any combination thereof.

6. The device of claim 1, wherein the die is optimized to reduce variance in a force required to compress the die onto the target starting material during the interaction, the variance being dependent at least in part on a design (e.g., design layout) of at least one relief of the die; and optionally wherein the design of the at least one relief is minimized such that (A) minimal extent of the target starting material is cut at each interaction with of the die with the target starting material upon operation of the device and / or (B) a similar extent of the target starting material is cut at each interaction with of the die with the target starting material upon operation of the device7. The device of claim 1, wherein the internal roller is configured to operatively couple with a die at least in part by using the attractive force; optionally wherein the attractive force comprises a magnetic force, mechanical force, hydraulic force, gas force, or any combination thereof; optionally wherein the gas force comprises a pneumatic force or vacuum; and optionally wherein the attractive force comprises a magnetic force.

8. The device of claim 1, wherein the device is configured to operate in an enclosure having an internal environment different from an ambient environment external to the enclosure, the product being susceptible to one or more reactive agents present in the ambient environment; optionally wherein the one or more reactive agents comprise oxygen, water, alcohol, thiol, sulfuric acid, phosphoric acid, carboxylic acid, hydrogen sulfide, any plurality thereof, or any combination thereof; optionally wherein the internal environment comprises argon, nitrogen, clean dry air, or any combination thereof; and optionally wherein the internal environment has a temperature, pressure, and / or one or more reactive agents, different than those in the ambient environment.

9. The device of claim 1 , wherein the at least one component of the device is configured for temperature conditioning; optionally wherein the at least one component comprises the internal roller, the supporting roller, the frame, or any combination thereof; optionally wherein the temperature conditioning is controlled; optionally wherein the temperature conditioning comprises heating; optionally wherein the temperature conditioning comprises cooling; optionally wherein the at least one component is operatively coupled to, or includes, one or more channels configured to alter a temperature of the at least one component; optionally wherein one or more channels are configured for flow of a fluid; optionally wherein the fluid comprises a gas, a liquid, a semisolid, or any combination thereof; wherein the one or more components comprise a rod configured for heat transfer; and optionally wherein the rod comprises an elemental metal or a metal alloy; optionally wherein the rod comprises silver, copper, aluminum, graphene, gold, aluminum nitride, or boron arsenide; optionally wherein alteration of the temperature of the at least one component is during use of the device to generate the product; optionally wherein alteration of the temperature of the at least onecomponent is controlled at least in part by a control system; optionally wherein the temperature conditioning is active; optionally wherein the temperature conditioning is; optionally wherein the temperature conditioning comprise heating; optionally wherein the temperature conditioning comprise cooling; optionally wherein the temperature conditioning facilitates increasing accuracy, fidelity, and / or integrity, of the product; optionally wherein the temperature conditioning facilitates reduces deformation with respect to the target starting material; optionally wherein the deformation is of a particulate material mass as part of the target starting material; optionally wherein the deformation comprises introducing one or more defects comprising cracks, dislocations, unwanted growth centers, any types thereof, or any combination thereof; and optionally wherein the unwanted growth centers comprise (a) crystallization centers, (b) metallurgical phases, (c) grown centers accumulation of a reduced phase of charge carriers, or (d) any plurality of types thereof, or (e) any combination thereof.

10. The device of claim 1, wherein the die comprises at least one coating configured to lessen the occurrence of portions of the target starting material adhering to the die after processing of the target starting material; and optionally wherein the coating comprises polytetrafluoroethylene, polyfluoroalkyl, perfluoroalkyl substances, non-stick ceramic coating, carbon steel, stainless steel, silicone, Gore-Tex, siloxane, silane, oxidized regenerated cellulose, any plurality of types thereof, or any combination thereof.

11. The device of claim 1, wherein the device is configured for integration with one or more other processes and / or mechanisms to fabricate a requested product from the product, a system comprising the product, or a system comprising the requested product; optionally wherein the other processes comprise deposition, compression, calendering, roll-to-roll, cutting, forming, machining, welding, punching, casing, depositing, drying, spraying, 3D printing, calendering, compressing, ablating, dicing, adhering (e.g., gluing), soldering, any plurality of types thereof, or any combination thereof; and optionally wherein to fabricate a requested product from the product comprise to manufacture.

12. The device of claim 1, wherein the device is configured to provide the product at least in part using an attractive force and / or a repulsive force; optionally wherein the attractive force comprises a magnetic force, mechanical force, hydraulic force, gas force, an electrostatic forced, or any combination thereof; and optionally wherein the gas force comprises a pneumatic force or vacuum; optionally wherein an element of the mechanical force may comprise a wiper, a shovel, a loader, a fork, a grappler, a mover, a broom, any plurality of types thereof or any combination thereof; optionally wherein the mechanical force is part of a robotic system; and optionally wherein the attractive force comprises a gravitational force of the ambient environment.

13. The device of claim 1, wherein the die and the target starting material include at leastone type of material in common; optionally wherein the target starting material comprises a current collector, and the at least one type of material is the material type of the current collector; and optionally wherein the target starting material comprises an end plate, and the at least one type of material is the material type of the end plate.

14. The device of claim 1, wherein the die comprises at least one harder material than the target starting material; optionally wherein the die comprises a high performing metal; optionally wherein the target starting material is devoid of a high performing metal; optionally wherein the high performing metal comprises stainless steel (e.g., 316), Inconel, titanium, tungsten, tool steel, platinum, rhodium, aluminum alloy, rhenium, carbon composite, any plurality of types thereof, or any combination thereof; and optionally wherein the carbon composite comprises an allotrope of elemental carbon.

15. The device of claim 1, wherein the supportive roller comprises (I) a harder material than that of the die and / or (III) a self-mending material.

16. The device of claim 1 , wherein the relative rotation of the die roller with respect to the supporting roller comprises rotation of the die roller in a first direction opposite to a section direction in which the supporting roller rotates.

17. The device of claim 1, wherein (a) an absolute value of the rotation of the die roller is (e.g., substantially) the same as that of the supporting roller, (b) a lateral length of the die roller is (e.g., substantially) the same as that of the supporting roller, (c) a diameter of the die roller is (e.g., substantially) the same as that of the supporting roller, (d) a first lateral length of an engagement portion the die roller with the target starting material, is (e.g., substantially) the same as a second lateral length of an engagement portion the supporting roller with the target starting material.

18. The device of claim 1, wherein (a) an absolute value of the rotation of the die roller is (e.g., substantially) the same as that of the supporting roller, (b) a lateral length of the die roller is different from that of the supporting roller, (c) a diameter of the die roller is different from that of the supporting roller, (d) a first lateral length of an engagement portion the die roller with the target starting material, is different from a second lateral length of an engagement portion the supporting roller with the target starting material; optionally wherein different is smaller; and optionally wherein different is larger.

19. The device of claim 1, wherein the die comprises an external surface and an opposing an internal surface, the internal surface of the die being operatively coupled with the internal roller to generate the die roller.

20. The device of claim 1, wherein the die is configured to generate one or more components of an energy manipulation device (e.g., as disclosed herein); optionally wherein the energy manipulation device comprises a battery (e.g., as disclosed herein); and optionally wherein the battery is a rechargeable battery (e.g., as disclosed herein).

21. The device of claim 1, wherein the product comprising an electrode, a counter electrode, a separator, or a divider, of the one or more battery cells; and optionally wherein a member of the product comprises a plurality of units having an aspect ratio of a length to a width of at least about 1:1 2:1, 4:1, 5:1 , 8:1, 10:1 , 15:1, 20:1, 50:1, 100:1 , 1000:1, or a higher aspect ratio; and optionally wherein a member of the product comprises a plurality of units having an aspect ratio of a length to a height of at least about 1:1 2: 1 , 4: 1 , 5: 1 , 8: 1 , 10:1, 15: 1 , 20: 1 , 50: 1 , 100: 1 , 1000: 1 , or a higher aspect ratio; and optionally wherein a battery of the battery cells comprises at least 1 , 2, 10, 20, 50, 100, 150, 200, 250, or 500 cells.

22. The device of claim 1, wherein the die is configured to cut battery cell components.

23. A method of fabrication, the method comprising: executing one or more operations to process the target starting material at least in part by using the device of any of claims 1 to 22; and optionally wherein processing the target material by the device is at least a portion of a manufacturing process including the product.

24. An apparatus for fabrication, the apparatus comprising: at least one controller configured for (a) operatively coupling with the device of any of claims 1 to 22, and (b) executing, or directing at least one component of the device, to execute one or more operations associated with the fabrication; optionally wherein the at least one controller is configured to operatively couple with a power source and / or with a communication platform; optionally wherein the fabrication comprises manufacturing; optionally wherein the manufacturing comprises roll to roll manufacturing; optionally wherein the fabrication is of a system that includes the product; optionally wherein the system comprises an energy manipulation device; and optionally wherein the energy manipulation device is a battery.

25. One or more non-transitory computer readable media comprising program instruction physically inscribed thereon, the program instructions, when read by one or more processors operatively coupled with the device of any of claims 1 to 22, are configured to (I) execute, or direct execution of, one or more operations associated with fabrication of the product, (II) the one or more operations comprising directing at least one component of the device to execute the one or more operations; optionally wherein the fabrication comprises manufacturing; optionally wherein the manufacturing comprises roll to roll manufacturing; optionally wherein the fabrication is of a system that includes the product; optionally wherein the system comprises an energy manipulation device; and optionally wherein the energy manipulation device is a battery.

26. A method comprising: (a) providing the device of any of claims 1 to 22, and (b) manufacturing, testing, storing, transporting, and / or using the device for fabrication of the product.

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