Inter-connect for electronic current collectors

Abstract

The present inventions relate to methods, systems, apparatuses, controllers, software, and composition of matter associated with connecting electrodes (e.g., a plurality of cathode structures) to a respective electrode (e.g., cathode) busbar within an electrode assembly of an energy storage device such as a (e.g., secondary) battery.

Description

INTER-CONNECT FOR ELECTRONIC CURRENTCOLLECTORS PRIORITY

[0001] This application claims priority from U.S. Patent Application Serial No. 18 / 424,239 filed January 26, 2024, which is incorporated herein by reference in its entirety. BACKGROUND

[0002] The present disclosure relates to methods and structures such as electrode assemblies including current limiters for use in energy storage devices such as (e.g., secondary) batteries, to energy storage devices employing such structures, and to apparatuses, program instructions, and methods associated with the devices, e.g., methods for manufacturing such structures and energy devices.

[0003] Some energy storage devices comprise one or more battery cells, each of the battery cells comprising an anode structure and a cathode structure separated by a gap. In an example, some energy storage devices, such as lithium-based secondary batteries, comprise a plurality of cells that each include an anode structure and a cathode structure separated by a separator structure. Within a (e.g., each) cell, the anode structure and cathode structure are respectively attached to anode and cathode busbars. The busbars connect battery cells together and connect the battery cells to the positive and negative terminals of the energy storage device, e.g., to enable a user to make use of the stored energy. A battery cell is also referred to herein as “cell.”

[0004] One approach for connecting an electrode (e.g., a cathode) structure to the electrode’s (e.g., cathode) busbar includes using a "D-slot” or opening in the busbar. During assembly, the electrode structure is extended through the opening in the electrode busbar and is then bent over to contact the outer surface of the electrode busbar opposite the main body of the electrode structure. This technique for connecting an electrode structure to the electrode busbar can bring certain challenges. Given the small scale of the structures, the electrode structure and / or electrode busbar openings may be broken, torn, or otherwise deformed during manufacturing. During assembly, it may be difficult to align and / or insert the electrode structures into the electrode busbar openings, e.g., particularly without causing further deformation or damage to the electrode structures and / or electrode openings. Other approaches, such as laser welding, can bring other drawbacks such as increased complexity and / or increased expense due to the equipment required. The electrode can be an anode or a cathode.

[0005] Some approaches to making structural and / or electrical connections between various components (e.g., structures) within an energy storage device may be applicable (e.g., only) to a subset of the device’s structures. For example, an adhesive may be used to attach ananode structure to an anode busbar. The adhesive may be limited to a material compatible with the energy storage device. In an example, the adhesive material is limited to (e.g., only) those materials compatible with the anode structure and anode busbar. The same adhesive type may operate compatibly with the anode material. The same adhesive type may degrade and / or break down, e.g., if used to affix a cathode structure to a cathode busbar.

[0006] In another approach, an adhesive is applied to the entire (e.g., full) surface of the cathode structure that is in contact with the cathode busbar. Such an approach may require a greater amount of adhesive, may require higher pressures (e.g., due to the larger surface area), and / or may cause non-uniformity of the resulting connection, e.g., due to material leaking and / or squeezing out from the sides of the connection between the cathode structure and the cathode busbar such as when pressure is applied.SUMMARY

[0007] In some aspects, the present disclosure resolves one or more of the aforementioned hardships. In some embodiments, the present disclosure provides solutions to curtail the aforementioned hardships. In some embodiments, the present inventions relate to method(s) (e.g., technique), device(s), apparatus(es), system(s), and design(s), which build a battery comprising cell(s). Methods, apparatuses, devices, program instructions, and structures, are disclosed herein for providing a structural connection between an electrode (e.g., cathode) structure and its respective electrode (e.g., cathode) busbar within an energy storage device.

[0008] In another aspect, provided herein is a connection of electrode (e.g., a plurality of cathode) structures to a respective electrode (e.g., cathode) busbar within an electrode assembly of an energy storage device such as a secondary battery. Each electrode structure includes a respective electrode active material layer and a current collector, wherein the electrode current collector has an end portion that extends beyond the electrode active material layer. The end portions of the electrode structures are attached to the electrode busbar via two adhesive material (e.g., tacky material such as polymer strips) that enable strong mechanical and electrical connections between the structures in clouded in the cell(s) and the respective electrode busbar. The electrode can be an anode or a cathode.

[0009] In another aspect, an electrode assembly of an energy storage device comprises a plurality of unit cells stacked in a stacking direction, each having an anode structure, a cathode structure, and a separator structure. In an example, the cathode structure comprises a cathode current collector and a cathode active material layer, and the cathode structure extends in the longitudinal direction perpendicular to the stacking direction. In an embodiment, an end portion of each cathode current collector of the plurality of cells extends beyond the cathode active material layer and the separator structure in the longitudinal direction. In an embodiments, the electrode assembly (e.g., also) includes a first adhesivepolymer strip and a second adhesive polymer strip, attached to the end portions of cathode current collectors, and a cathode busbar attached to the end portions of cathode current collectors, e.g., through, or using, the first adhesive polymer strips and the second adhesive polymer strip. Such structure may enable a mechanical and electrical connection between the cathode structure and the cathode busbar without requiring d-slots, thereby reducing the risks and / or issues, associated with deformation of the d-slots during manufacturing and assembly. The disclosed inventions (e.g., methods and structures) enable the mechanical and electrical connection between the electrode structure and its associated electrode busbar using materials suitable for use with the electrode materials, e.g., between the cathode structure and the cathode busbar using materials suitable for use with the cathode materials.

[0010] Use of the first adhesive strip and of the second adhesive strip (e.g., rather than applying the adhesive to the entire surface of the electrode structure contacting with the electrode busbar), can enable a mechanical connection, electrical connection, or mechanical and electrical connection, that is more reliable, reproducible, uniform, and / or uses less adhesive material. Such solution may (e.g., also) enable a more uniform connection, the use of lower pressures, and / or reduced leaking of adhesive out the sides of the connection such as when pressure is applied. In an example, use of the first adhesive strip and of the second adhesive strip, rather than applying the adhesive to the entire surface of the cathode structure that is in contact with the cathode busbar, enables for a mechanical and electrical connection using less adhesive material.

[0011] In some examples, the first and second adhesive polymer strips, each comprise one type of adhesive material such as a neat polymer, such as without (e.g., any) suspended conductive material. In some examples, the first and second adhesive polymer strips may be thermoplastic adhesives or thermosets. In some examples, the first and second adhesive polymer strips may be separated from each other (a) (e.g., substantially) in a direction perpendicular to the stacking direction of the cells, and (b) (e.g., substantially) perpendicular to the longitudinal direction of the cathode structures. The section of the electrode (e.g., cathode) structure between the first and second adhesive polymer strips may be a middle section, which may be attached directly to the electrode (e.g., cathode) busbar (i.e., not through the adhesive), such as by a connecting methodology such as by welding. In some examples, the first and second adhesive polymer strips may each include (a) a base material such as a polymer and (b) a conductive filler. The conductive filler may comprise aluminum, titanium, titanium nitride, carbon, stainless steel, or a noble metal. A shape of the conductive filler may comprise spheres, flakes, fibers, hollow coated particles, solid coated particles, or a conductive mesh.

[0012] In another aspect, a method of assembling an electrode is disclosed. The example method can comprise stacking a plurality of unit cells in a stacking direction, each of the unit cells comprising an anode structure, a separator structure, and an electrode (e.g., cathode) structure. The electrode (e.g., cathode) structure of each unit cell comprises a electrode (e.g., cathode) current collector and an electrode (e.g., cathode) active material layer, wherein (1) the electrode (e.g., cathode) structure extends in a longitudinal direction perpendicular to the stacking direction, and (2) an end portion of the electrode (e.g., cathode) current collector extends beyond the electrode (e.g., cathode) active material layer and the separator structure in the longitudinal direction. The example method can include attaching a first adhesive polymer strip to the end portion of the electrode (e.g., cathode) current collector of each unit cell of the plurality of unit cells, and attaching a second adhesive polymer strip to the end portion of the electrode (e.g., cathode) current collector of each unit cell of the plurality of unit cells, wherein the first adhesive polymer strip and the second adhesive polymer strip are separated in a third direction perpendicular to both the stacking direction and to the longitudinal direction. The method further comprises attaching an electrode (e.g., cathode) busbar to the end portions of the electrode (e.g., cathode) current collectors through the first adhesive polymer strip and the second adhesive polymer strip. In some embodiments, the electrode is a cathode. In some embodiments, the electrode is an anode. In some examples, the first adhesive polymer strip and the second adhesive polymer strip each comprise one type of an adhesive material such as a neat polymer. In some examples, the first adhesive polymer strip and the second adhesive polymer strip each comprise a thermoplastic adhesive. In some examples, the first adhesive (e.g., polymer) strip and the second adhesive (e.g., polymer) strip, each comprise a thermoset. In some examples, the example method comprises attaching a middle sections of the end portions of the electrode (e.g., cathode) current collectors directly to the electrode (e.g., cathode) busbar, the middle sections extending between the first adhesive polymer strip and the second adhesive polymer strip. In some examples, the example method includes contacting (e.g., welding) the middle section of the end portions of the cathode current collectors to the cathode busbar. In some examples, the first adhesive polymer strip and the second adhesive polymer strip are (e.g., substantially) parallel and extend in the stacking direction. In some examples, the first adhesive polymer strip and the second adhesive polymer strip each comprises a base adhesive material (e.g., polymer) and a conductive filler. In some examples, the conductive filler comprises an aluminum filler, a titanium filler, a titanium nitride filler, a carbon-based filler, a stainless-steel filler, or a noble metal filler. In some examples, a shape of the conductive filler comprises one or more of spheres, flakes, fibers, hollow coated particles, solid coated particles, or a conductive mesh.

[0013] In another aspect, a (e.g., secondary) battery comprises a battery enclosure, an electrode assembly, and an electrolyte within the battery enclosure. In some examples, the electrode assembly comprises a plurality of unit cells stacked in a stacking direction, each of the unit cells comprising a counter electrode (e.g., an anode) structure, an optional separator structure, and an electrode (e.g., cathode) structure. The electrode (e.g., cathode) structure of each unit cell comprises a electrode (e.g., cathode) current collector and an electrode (e.g., cathode) active material layer, wherein (1 ) the electrode (e.g., cathode) structure extends in a longitudinal direction perpendicular to the stacking direction, and (2) an end portion of the electrode (e.g., cathode) current collector extends in the longitudinal direction beyond the electrode (e.g., cathode) active material layer and any separator structure. The electrode assembly also includes a first adhesive polymer strip attached to the end portion of the electrode (e.g., cathode) current collector of each unit cell of the plurality of unit cells, a second adhesive polymer strip attached to the end portion of the electrode (e.g., cathode) current collector of each unit cell of the plurality of unit cells, wherein the first adhesive polymer strip and the second adhesive polymer strip are separated in a third direction perpendicular to both the stacking direction and the longitudinal direction, and an electrode (e.g., cathode) busbar attached to the end portions of the electrode (e.g., cathode) current collectors through the first adhesive polymer strip and the second adhesive polymer strip. The electrode can be a cathode or an anode.

[0014] In some examples, the first and second adhesive polymer strips may function as a current limiting mechanism within the energy storage device. In example of the current limiting mechanism may be referred to as a BrakeFlow™ mechanism (trademark owned by Enovix Corporation). The current limiting mechanism may be used to increase safety and / or control of the energy storage device. The current limiting mechanism may be used to hinder (e.g., prevent) thermal runaway in batteries, battery packs, battery storage devices, and / or in battery cells. Using an energy storage device like those described herein, includes the risk that energy is released in an undesirable and / or uncontrolled manner through an unintentional or through an intentional action, e.g., through accident, abuse, exposure to extreme conditions, or the like. When the current flow between the electrode (e.g., cathode) current collectors and the respective electrode (e.g., cathode) busbar, increases beyond a threshold level (e.g., due to accident, abuse, etc.), the first and second adhesive polymer strips may break down and / or change their conductive properties, e.g., thereby reducing or at least partially eliminating the electrical connection. In turn, the reduced electrical connection may act.to reduce further release of energy.

[0015] In another aspect, an electrode assembly comprising: a plurality of unit cells stacked in a stacking direction, each of the plurality of unit cells comprising an anode structure, a separator structure, and a cathode structure, wherein the cathode structure of each unit cellcomprises: a cathode current collector; and a cathode active material layer, wherein (1) the cathode structure extends in a longitudinal direction perpendicular to the stacking direction, and (2) an end portion of the cathode current collector extends beyond the cathode active material layer and the separator structure in the longitudinal direction; a first adhesive polymer strip attached to the end portion of the cathode current collector of each unit cell of the plurality of unit cells; a second adhesive polymer strip attached to the end portion of the cathode current collector of each unit cell of the plurality of unit cells, wherein the first adhesive polymer strip and the second adhesive polymer strip are separated in a third direction perpendicular to both the stacking direction and the longitudinal direction; and a cathode busbar attached to the end portions of the cathode current collectors through the first adhesive polymer strip and the second adhesive polymer strip. In some embodiments, the first adhesive polymer strip and the second adhesive polymer strip each comprise a neat polymer. In some embodiments, the first adhesive polymer strip and the second adhesive polymer strip each comprise a thermoplastic adhesive. In some embodiments, the first adhesive polymer strip and the second adhesive polymer strip each comprise a thermoset. In some embodiments, middle sections of the end portions of the cathode current collectors are attached directly to the cathode busbar, the middle sections extending between the first adhesive polymer strip and the second adhesive polymer strip. In some embodiments, the middle sections of the end portions of the cathode current collectors are welded to the cathode busbar. In some embodiments, the first adhesive polymer strip and the second adhesive polymer strip are parallel and extend in the stacking direction. In some embodiments, the first adhesive polymer strip and the second adhesive polymer strip each comprises a base polymer and a conductive filler. In some embodiments, the conductive filler comprises one of an aluminum filler, a titanium filler, a titanium nitride filler, a carbonbased filler, a stainless-steel filler, or a noble metal filler. In some embodiments, a shape of the conductive filler comprises one of spheres, flakes, fibers, hollow coated particles, solid coated particles, or a conductive mesh. A method of assembling an electrode assembly comprising: stacking a plurality of unit cells in a stacking direction, each of the plurality of unit cells comprising an anode structure, a separator structure, and a cathode structure, wherein the cathode structure of each unit cell comprises: a cathode current collector; and a cathode active material layer, wherein (1) the cathode structure extends in a longitudinal direction perpendicular to the stacking direction, and (2) an end portion of the cathode current collector extends beyond the cathode active material layer and the separator structure in the longitudinal direction; attaching a first adhesive polymer strip to the end portion of the cathode current collector of each unit cell of the plurality of unit cells; attaching a second adhesive polymer strip to the end portion of the cathode current collector of each unit cell of the plurality of unit cells, wherein the first adhesive polymer strip and the second adhesivepolymer strip are separated in a third direction perpendicular to both the stacking direction and the longitudinal direction; and attaching a cathode busbar to the end portions of the cathode current collectors through the first adhesive polymer strip and the second adhesive polymer strip. In some embodiments, the first adhesive polymer strip and the second adhesive polymer strip each comprise a neat polymer. In some embodiments, the first adhesive polymer strip and the second adhesive polymer strip each comprise a thermoplastic adhesive. In some embodiments, the first adhesive polymer strip and the second adhesive polymer strip each comprise a thermoset. In some embodiments, the method comprises: attaching middle sections of the end portions of the cathode current collectors directly to the cathode busbar, the middle sections extending between the first adhesive polymer strip and the second adhesive polymer strip. In some embodiments, the method comprises: welding the middle sections of the end portions of the cathode current collectors to the cathode busbar. In some embodiments, the first adhesive polymer strip and the second adhesive polymer strip are parallel and extend in the stacking direction. In some embodiments, the first adhesive polymer strip and the second adhesive polymer strip each comprises a base polymer and a conductive filler, and wherein the conductive filler comprises one of an aluminum filler, a titanium filler, a titanium nitride filler, a carbon-based filler, a stainless-steel filler, or a noble metal filler. In some embodiments, a shape of the conductive filler comprises one of spheres, flakes, fibers, hollow coated particles, solid coated particles, or a conductive mesh.

[0016] In another aspect, a secondary battery comprising a battery enclosure, an electrode assembly, and an electrolyte within the battery enclosure, wherein the electrode assembly comprises: a plurality of unit cells stacked in a stacking direction, each of the plurality of unit cells comprising an anode structure, a separator structure, and a cathode structure, wherein the cathode structure of each unit cell comprises: a cathode current collector; and a cathode active material layer, wherein (1) the cathode structure extends in a longitudinal direction perpendicular to the stacking direction, and (2) an end portion of the cathode current collector extends beyond the cathode active material layer and the separator structure in the longitudinal direction; a first adhesive polymer strip attached to the end portion of the cathode current collector of each unit cell of the plurality of unit cells; a second adhesive polymer strip attached to the end portion of the cathode current collector of each unit cell of the plurality of unit cells, wherein the first adhesive polymer strip and the second adhesive polymer strip are separated in a third direction perpendicular to both the stacking direction and the longitudinal direction; and a cathode busbar attached to the end portions of the cathode current collectors through the first adhesive polymer strip and the second adhesive polymer strip.

[0017] In another aspect, a device for energy manipulation, the device comprises: a first battery cell comprising a first electrode separated from a first counter electrode by a first gap, the first electrode including a first electrode current collector comprising a first electrode internal portion that extends into, and / or contacts, a first electrode external portion that is a first electrode tab, the first electrode internal portion contacting a first electrode active material, the first electrode tab being (e.g., substantially) devoid of the first electrode active material; and an optional second battery cell comprising a second electrode separated from a second counter electrode by a second gap, the second electrode including a second electrode current collector comprising a second electrode internal portion that extends into, and / or contacts, a second electrode external portion that is a second electrode tab, the second electrode internal portion contacting a second electrode active material, the second electrode tab being (e.g., substantially) devoid of the second electrode active material, wherein: (a) the first electrode current collector having a first axis extending from an exposed end of the first electrode internal portion to an exposed end of the first electrode tab opposing the exposed end of the first electrode internal portion, the first electrode tab comprising a first shape that diminishes along the first axis; (b) the first electrode tab comprising a first portion that buckles along the first axis; (c) the first electrode tab and the second electrode tab contacting a busbar configured for electrical current flow therethrough, the busbar comprising one or more perforations extending from an exposed face of the busbar to an internal face of the busbar, the internal face contacting the first electrode tab and the second electrode tab; (d) the busbar configured to accommodate the first electrode tab and the second electrode tab to facilitate the electrical current flow therethrough and through the busbar, the busbar comprising an indentation configured to accommodate at least the first electrode tab and the second electrode tab; (e) the first electrode tab being configured to bend relative to the first electrode internal portion in a forward direction, and the second electrode tab being configured to bend relative to the second electrode internal portion in a backwards direction opposing the forward direction; or (f) any combination of (a), (b), (c), (d) and (e). In some embodiments, the first shape diminishes in shape, cross section, volume, or any combination thereof. In some embodiments, the first axis is a median axis of the first electrode current collector. In some embodiments, the first shape diminishes along the first axis linearly, or exponentially (e.g., or otherwise non-linearly). In some embodiments, the first shape diminishes (e.g., substantially) symmetrically about the first axis. In some embodiments, the first electrode current collector has a width normal the first axis, the width being of a face of the current collector contacting the first electrode active material. In some embodiments, width of the first shape diminishes along the first axis. In some embodiments, width the exposed end of the first electrode tab is (e.g., substantially) the width of the first electrode internal portion. In some embodiments, width the exposed endof the first electrode tab is different from the width of the first electrode internal portion. In some embodiments, width the exposed end of the first electrode tab is smaller than the width of the first electrode internal portion. In some embodiments, the width of the first shape diminishes symmetrically along the first axis. In some embodiments, the width of the first shape diminishes linearly, or exponentially (e.g., or otherwise non-linearly). In some embodiments, the first electrode current collector has a face contacting the first electrode active materia). In some embodiments, a circumference of the face of the first shape comprises a curvature. In some embodiments, a circumference of the face of the first shape comprises a straight line. In some embodiments, a circumference of the face of the first shape comprises a curvature and a straight line. In some embodiments, the exposed end of the first electrode tab is truncated. In some embodiments, the first electrode tab comprises a second shape that (e.g., substantially) does not diminish (e.g., along the first axis). In some embodiments, the second shape (e.g., substantially) does not diminish in shape, cross section, volume, or any combination thereof. In some embodiments, the second shape (e.g., substantially) retains in shape, cross section, volume, or any combination thereof. In some embodiments, the first electrode current collector has a width normal the first axis, the width being of a face of the current collector contacting the first electrode active material. In some embodiments, the width of the second shape is different from the width of the first electrode internal portion. In some embodiments, the width of the second shape is smaller than the width of the first electrode internal portion. In some embodiments, the width of the second shape is (e.g., substantially) the width of the first electrode internal portion. In some embodiments, the first electrode tab comprises a third shape. In some embodiments, the width of the third shape is (e.g., substantially) the width of (i) the first electrode internal portion or (ii) a minimal value of the width of the first shape. In some embodiments, the width of the third shape includes the exposed end of the first electrode tab. In some embodiments, the first portion buckles in an alternating fashion. In some embodiments, the first portion buckles in a manner similar to a zigzag, sinus, or top-hat. In some embodiments, the first portion buckles in a manner similar to an English letter S, English letter Z, the combination of letters “Lr,” or including a Greek letter n,. In some embodiments, the first portion buckles along the first axis. In some embodiments, the first portion buckles along the first axis in (a) a diminishing amplitude, (b) diminishing pitch, or (c) any combination of (a) and (b). In some embodiments, the first portion diminishingly buckles along the first axis. In some embodiments, the first portion that diminishingly buckles, contacts the first electrode internal portion. In some embodiments, the first portion that diminishingly buckles excludes the first exposed end of the first electrode tab. In some embodiments, the first portion that diminishingly buckles has the first exposed end of the first electrode tab. In some embodiments, the perforations are configured to release tension, pressure, and / or gasduring an operation of the device. In some embodiments, the operation of the device comprises electrically charging and / or electrically discharging the device. In some embodiments, the one or more perforations comprises a set of perforations. In some embodiments, the busbar comprises a length axis, the first electrode tab. In some embodiments, the second electrode tab being disposed along the length axis. In some embodiments, the set of perforations are arranged (e.g., substantially) normal to the length axis. In some embodiments, the set of perforations are arranged (e.g., substantially) normal to the length axis (e.g., substantially) symmetrically. In some embodiments, the busbar comprises a plurality of perforation sets comprising the set of perforations, and wherein each set of the plurality of perforation sets is arranged along the length axis of the busbar. In some embodiments, (A) sets of the plurality of perforation sets are arranged in an equidistant manner and / or (B) perforations of the set of perforations are arranged in an equidistant manner. In some embodiments, the indentation is symmetrically disposed along a length axis of the busbar, and wherein upon assembly of the device, the first electrode tab and the second electrode tab are disposed along the length axis of the busbar. In some embodiments, the busbar comprises at least two material classes. In some embodiments, the material classes (I) include an elemental metal, a metal alloy, an allotrope of elemental carbon, any plurality thereof, or any combination thereof and / or (I) include a composite material, a non-composite material, any plurality thereof, or any combination thereof. In some embodiments, the first electrode tab is configured to bend at a smallest first angle of at most about 140 degrees relative to the first electrode internal portion, and wherein the second electrode tab is configured to bend at a smallest second angle of at most about 140 degrees relative to the second electrode internal portion. In some embodiments, the smallest first angle and / or the smallest second angle is at most about 100 degrees. In some embodiments, the smallest first angle and / or the smallest second angle is at most about 95 degrees. In some embodiments, a first set of electrode tabs include the first electrode tab, and wherein a second set of electrode tabs include the second electrode tab, and wherein the first set of electrode tabs is configured to bend relative to the first internal portion in the forward direction, and the second set of electrode tabs being configured to bend relative to the second electrode internal portion in the backwards direction. In some embodiments, the busbar comprises at least two material types, the at least two material types belonging to a class of the at least two material classes. In some embodiments, the at least two material types comprise elemental metals, or metal alloys. In some embodiments, the device is a battery or includes the battery. In some embodiments, the battery is a secondary (e.g., rechargeable) battery. In some embodiments, the first counter-electrode including a first counter-electrode current collector comprising a first counter-electrode internal portion that extends into, and / or contacts, a first counter-electrode external portion that is a first counter-electrode tab, the first counter-electrode internal portion contacting a first counter-electrode active material, the first counter-electrode tab being (e.g., substantially) devoid of the first counter-electrode active material; and an optional second battery cell comprising a second counter-electrode separated from a second counter counter-electrode by a second gap, the second counter-electrode including a second counter-electrode current collector comprising a second counter-electrode internal portion that extends into, and / or contacts, a second counter-electrode external portion that is a second counter-electrode tab, the second counter-electrode internal portion contacting a second counter-electrode active material, the second counter-electrode tab being (e.g., substantially) devoid of the second counterelectrode active material. In some embodiments, (A) the first counter-electrode current collector having a first axis extending from an exposed end of the first counter-electrode internal portion to an exposed end of the first counter-electrode tab opposing the exposed end of the first counter-electrode internal portion, the first counter-electrode tab comprising a first shape that diminishes along the first axis; (B) the first counter-electrode tab comprising a first portion that buckles along the first axis; (C) the busbar is an electrode busbar, the first counter-electrode tab and the second counter-electrode tab contacting a counter-electrode busbar configured for electrical current flow therethrough, the counter-electrode busbar comprising one or more perforations extending from an exposed face of the counterelectrode busbar to an internal face of the counter-electrode busbar, the internal face contacting the first counter-electrode tab and the second counter-electrode tab; (D) the counter-electrode busbar configured to accommodate the first counter-electrode tab and the second counter-electrode tab to facilitate the electrical current flow therethrough and through the counter-electrode busbar, the counter-electrode busbar comprising an indentation configured to accommodate at least the first counter-electrode tab and the second counterelectrode tab; (E) the first counter-electrode tab being configured to bend relative to the first counter- electrode internal portion in the forward direction, and the second counter-electrode tab being configured to bend relative to the second counter- electrode internal portion in the backward direction; or (F) any combination of (A), (B), (C), (D) and (E). In some embodiments, a first set of counter-electrode tabs include the first counter-electrode tab, and wherein a second set of counter-electrode tabs include the second counter-electrode tab, and wherein the first set of counter-electrode tabs is configured to bend relative to the first internal portion in the forward direction, and the second set of counter-electrode tabs being configured to bend relative to the second internal portion in the backwards direction. In some embodiments, (a) the device comprises a casing housing the first battery cell and the second battery cell, (b) the first battery cell and the second battery cell are horizontally stacked, (c) the device configured for quicker heat dissipation as compared to similar devices currently available, (d) the device being configured to minimize plating of charge carriers, (e) thedevice being configured for pre-loading of the charge carriers, (f) the device being configured for (e.g., 3C) fast charging, the electrode active material comprises silicon, the electrode being an anode, (f) the device being configured for a thinner anode as compared to conventional anodes comprising graphite, or (g) any combination thereof. In some embodiments, the casing is an anisotropic constraint.

[0018] In another aspect, an apparatus for energy manipulation in any of the above devices, the apparatus comprises: at least one controller configured (A) for operatively coupling with the device, and (B) to execute, or direct at least one component of the device to execute, one or more operations associated with the energy manipulation, and optionally wherein the at least one controller is configured to operatively couple to a power source and / or with a communication platform.

[0019] 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 one or more components of device in any of the above devices, are configured to execute, or direct execution of, one or more operations associated with the device and / or with the energy manipulation.

[0020] In another aspect, a method of fabricating the device in any of the above devices, the method comprising: operatively coupling the first tab and the second tab to facilitate the electrical current flow.

[0021] In another aspect, a method for energy manipulation in the energy storage device, the method comprises: (a) providing any of the above devices, and (b) storing the device, maintaining the device, transporting the device, pre-charging the device, or using the device for the energy manipulation such as electrical charge and / or discharge.

[0022] In another aspect, an apparatus for energy manipulation in the device, the apparatus comprises: at least one controller configured (a) for operatively coupling with any of the above devices, and (b) executing, or directing execution of, at least one component of the device to execute one or more operations associated with the energy manipulation. In some embodiments, the at least one controller is configured to operatively couple to a power source and / rot with a communication platform.

[0023] 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 one or more components of any of the above devices, are configured to execute, or direct execution of, one or more operations associated with the energy manipulation.

[0024] In another aspect, a method for fabricating the device for energy manipulation such as for charging and / or discharging.

[0025] In another aspect, an apparatus for energy manipulation in the device, the apparatus comprises: at least one controller configured execution, or directing execution of, one or more operations to effectuate any of the above methods to fabricate the device. In some embodiments, the at least one controller is configured to operatively couple to a power source and / rot with a communication platform.

[0026] 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, are configured to execute, or direct execution of, one or more operations of any of the above methods to fabricate the device.

[0027] 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.

[0028] In another aspect, a system for effectuating the methods, operations of an apparatus, operation of a device, and / or operations inscribed by non-transitory computer readable program instructions (e.g., inscribed on a media / medium), disclosed herein.

[0029] 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).

[0030] 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 methods disclosed herein. In some embodiments, the program instructions are inscribed on at least one medium (e.g., on a medium or on media).

[0031] 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).

[0032] 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.

[0033] 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.

[0034] 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).

[0035] 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 same processor 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.

[0036] 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.

[0037] 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).

[0038] 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.

[0039] 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.

[0040] 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 direct operation of the other component at least in part for participation of the other component in a method disclosed herein.

[0041] 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.

[0042] In some embodiments, the program instructions are of a computer product.

[0043] 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.

[0044] 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 departingfrom the disclosure. Accordingly, the drawings and description are to be regarded as illustrative in nature, and not as restrictive.INCORPORATION BY REFERENCE

[0045] 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.

[0046] 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

[0047] 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 and should 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.

[0048] The novel features of the present disclosure are set forth with particularity in the appended claims. 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:

[0049] Fig. 1 is a simplified diagram of an example electrode assembly for cycling between a charged state and a discharged state in a secondary battery, in accordance with some implementations of the disclosure;

[0050] Fig. 2 is a simplified diagram of another example electrode assembly for cycling between a charged state and a discharged state in a secondary battery, in accordance with some implementations of the disclosure;

[0051] Fig. 3A is a perspective view of an electrode structure and two adhesive polymer strips, in accordance with some implementations of the disclosure;

[0052] Fig. 3B is a perspective view of the electrode structure of Fig. 3A affixed to an electrode busbar via the two adhesive polymer strips, in accordance with some implementations of the disclosure;

[0053] Fig. 4A is an end view of a plurality of electrode structures affixed to an electrode busbar via two adhesive polymer strips, in accordance with some implementations of the disclosure;

[0054] Fig. 4B is a side view of the plurality of electrode structures affixed to the electrode busbar via the two adhesive polymer strips of Fig. 4A, in accordance with some implementations of the disclosure;

[0055] Fig. 5 is a perspective view of an end of a stacked cell including a plurality of electrode structures affixed to an electrode busbar via adhesive polymer strips, in accordance with some implementations of the disclosure;

[0056] Fig. 6 is a perspective view of an end of a stacked cell including a plurality of electrode structures affixed to an electrode busbar via adhesive polymer strips and via welds, in accordance with some implementations of the disclosure;

[0057] Fig. 7 illustrates a closeup view of the tabs of a plurality of electrode structures before being affixed to an electrode busbar, in accordance with some implementations of the disclosure;

[0058] Fig. 8 is an illustrative flowchart of a process for assembling an electrode assembly, in accordance with some implementations of the disclosure;

[0059] Fig. 9 schematically shows various battery cells;

[0060] Fig. 10 schematically shows various folding options, and a current collector;

[0061] Fig. 11 schematically shows cells of batteries;

[0062] Fig. 12 schematically shows exploded views of cells and constraints;

[0063] Fig. 13 schematically shows battery components;

[0064] Fig. 15 shows battery components;

[0065] Fig. 16 shows battery components;

[0066] Fig. 17 shows images of battery components;

[0067] Fig. 18 shows an image of battery components;

[0068] Fig. 19 shows battery components;

[0069] Fig. 20 schematically shows battery components;

[0070] Fig. 21 shows images of battery components;

[0071] Fig. 22 shows processes in various stages of a battery;

[0072] Fig. 23 shows charge curves for various half cells;

[0073] Fig. 24 shows images of battery cells;

[0074] Fig. 25 shows pre-charging of battery cells

[0075] Fig. 26 shows various graphs relating to battery performance;

[0076] Fig 27 shows images of battery components;

[0077] Fig 28 shows images of battery components;

[0078] Fig 20 shows images of battery components;

[0079] Fig 30 shows images of battery components;

[0080] Fig. 31 schematically shows a control system; and

[0081] Fig. 32 schematically shows a processing system.

[0082] 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

[0083] 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.

[0084] 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.

[0085] 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. The terminology 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.

[0086] 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.

[0087] 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.”

[0088] 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).

[0089] 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.

[0090] 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, a radius, a spherical equivalent radius, or a radius of a bounding circle, or a radius of a bounding sphere.

[0091] 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 reversibly opening 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.

[0092] While the disclosure refers to a cathode as an electrode, the electrode may be an anode, as applicable.

[0093] As noted herein, implementations of the present disclosure relate to secondary batteries, the structures that make up the 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 secondary battery may refer to the negative electrode in a secondary battery. “Anode material” or “anodically active” as used herein may refer to a material or materials suitable for use as the negative electrode of a secondary battery. The term “cathode” as used herein in the context of a secondary battery may refer to the positive electrode in a secondary battery. "Cathode material” or “cathodically active” as used hereinmay refer to a material or materials suitable for use as the positive electrode of a secondary battery.

[0094] 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. 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.

[0095] Figs. 1 and 2 illustrate simplified diagrams of a first example electrode assembly 100 and a second example electrode assembly 200 for cycling between a charged state and a discharged state in a battery. FIG 1 illustrates an electrode assembly 100, wherein the electrode and counter-electrode structure 102 and 104 are connected to the electrode and counter-electrode busbars 108 and 110 directly, without a current limiter positioned in between. Fig. 2 illustrates an electrode assembly 200, which may be similar or identical to electrode structure 100 in many respects, but which illustrates the electrode and counterelectrode structures 102 and 104 connected to the electrode and counter-electrode busbars 108 and 110 via current limiters 206 and 207, respectively. Additionally, in Fig. 2, the separator material 105 has been removed to avoid overcomplicating the illustration. It should be appreciated, however, that the electrode assembly 200 may include a separator material similar or identical to that shown in Fig. 1 , positioned between each pair of electrode and counter-electrode structures 102 and 104.

[0096] Figs. 1 and 2 illustrate examples of electrode assemblies 100 and 200 each having a population of electrode structures 102 and a population of counter-electrode structures 104, an electrode busbar 108, and a counter-electrode busbar 110. Electrode assembly 100 is further illustrated including a population of separator structures 105. Electrode assembly 200 is further illustrated including current limiters 206 and 207. The example implementations shown in Figs. 1 and 2 are electrode assemblies suitable for use in a three-dimensional secondary battery, in which the electrode structures 102 and counter-electrode structures 104 each extend primarily along a width W (or longitudinal direction) and height H of the assembly, and are separated from each other along a length L (or stacking direction). In other implementations, the electrode assemblies 100 and / or 200 may be for use in a laminar secondary battery.

[0097] A voltage difference V exists between adjacent electrode structures 102 and counterelectrode structures 104, which adjacent pairs may be considered a unit cell. Each unit cell has a capacity C determined by the makeup and configuration of the electrode structures102 and counter-electrode structures 104. In an example implementation, each unit cell may produce a voltage difference of about 4.35 volts. In other implementations, each unit cell has a voltage difference somewhere in the range of about 0.5-5.0 volts, or any other suitable voltage. During cycling between charged and discharged states, the voltage may vary, for example, between about 2.5 volts and about 4.35 volts. The capacity C of a unit cell in an example implementation may be about 25 mAh. In other implementations, the capacity C of a unit cell may be about 50 mAh, less than 50 mAh, or any other suitable capacity. In some implementations, the capacity C of a unit cell may be up to about 500 mAh.

[0098] In the illustrated implementations of Figs. 1 and 2, the electrode structures 102 and counter-electrode structures 104 are generally rectangular and arranged in an interdigitated structure. That is, the electrode structures 102 and counter-electrode structures 104 extend from opposite electrode and counter-electrode busbars 108, 110 and alternate along the stacking direction L. In other implementations, other shapes and arrangements of the electrode structures 102 and counter-electrode structures 104 may be used. For example, the electrode assemblies 100 and / or 200 (and the batteries within which they are included) may have any of the shapes and / or arrangements described or shown in U.S. Pat. No. 9,166,230, which is hereby incorporated by reference in its entirety.

[0099] Each member of the population of electrode structures 102 includes an electrode active material 112 and an electrode current collector 114. In the example of Fig. 1 , the electrode structures 102 are electrically connected in parallel to the electrode busbar 108 without a current limiter in between. In the example of Fig. 2, the electrode structures 102 are electrically connected in parallel to the electrode busbar 108 via current limiters 206. The electrode structures 102 may be anodic or cathodic, but all of the electrode structures 102 in the population are of the same type (anodic or cathodic) in the example implementations shown in Figs. 1 and 2. In some other implementations, the electrode structures 102 may include anodic and cathodic structures. Each member of the population of counter-electrode structures 104 includes a counter-electrode active material 116 and a counter-electrode current collector 118. In Fig. 1 , the counter-electrode structures 104 are electrically connected in parallel to the counter-electrode busbar 110, without a current limiter in between. In Fig. 2, the counter-electrode structures 104 are electrically connected in parallel to the counter-electrode busbar 110 via current limiters 207. The counter-electrode structures 104 are all of the same type (anodic or cathodic) in the example implementations of Figs. 1 and 2 and are of the opposite type to the electrode structures 104. In some other implementations, the counter-electrode structures 102 may include anodic and cathodic structures.

[0100] Although only two electrode structures 102 and two counter-electrode structures 104 are shown in Figs. 1 and 2, the electrode assemblies 100 and / or 200 may have any numberof electrode structures 102 and counter-electrode structures 104. The populations of electrode structures 102 and counter-electrode structures 104 will generally include the same number of members but may include different numbers of electrode structures 102 and counter-electrode structures 104 in some implementations. For example, some implementations may begin and end with the same electrode structure 102 or counterelectrode structure, resulting in one more electrode structure 102 or counter-electrode structure. In some implementations, the populations of electrode structures 102 and counterelectrode structures 104 include at least twenty members each. Some implementations include populations of electrode structures 102 and counter-electrode structures 104 having about 10 members each, between 10 and 25 members each, between 25 and 250 members each, between 25 and 150 members each, between 50 and 150 members each, or up to 500 members each. In some implementations, the electrode structures 102 or the counter electrode structures 104 do not include an active material when discharged, and only the other of the counter electrode structures 104 or the electrode structures 102 includes an active material when discharged.

[0101] The cathodic type of the electrode structure 102 or the counter-electrode structure 104 includes a current collector 114 or 118 that is a cathode current collector. The (e.g., cathode) current collector material may comprise aluminum, nickel, cobalt, titanium, tungsten, carbon, chromium, gold, Nickel Phosphorus alloy (NiP), palladium, platinum, rhodium, ruthenium, silicon, alloys thereof, or any other material suitable for use as an electrode (e.g., cathode) current collector such as a layer thereof. In some implementations, the cathode current collector may have an electrical conductivity of at least about 103 Siemens / cm. However, it should be appreciated that in other implementations, the cathode current collector may have an electrical conductivity that is greater or less than 103 Siemens / cm. The anodic type of the electrode structure 102 or the counter-electrode structure 104 may include a current collector 114 or 118, which is an anode current collector. The (e.g., anode) current collector may comprise a conductive material such as copper, carbon, nickel, stainless steel, cobalt, titanium, and tungsten, alloys thereof, or any other material suitable as an electrode (e.g., an anode) current collector layer.

[0102] The cathodic type of the electrode structure 102 or the counter-electrode structure 104 may include an active material 112 or 116 that is a cathodically active material. The cathodically active material may be an intercalation-type chemistry active material, a conversion chemistry active material, and / or a combination thereof. Example conversion chemistry materials may include, but are not limited to, S (or U2S in the lithiated state), LiF, Fe, Cu, Ni, FeF2, FeOdF3.2d, FeFa, C0F3, C0F2, CUF2, NiFa, where 0<d 0.5, and the like.

[0103] Example cathodically active materials may also include any of a wide range of intercalation type cathodically active materials. For example, for a lithium-ion battery, thecathodically active material may comprise a cathodically active material selected from transition metal oxides, transition metal sulfides, transition metal nitrides, lithium-transition metal oxides, lithium-transition metal sulfides, 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 metai elements having a d-shell or f- shell. Specific examples of such metal element are 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, 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 charge carriers may comprise lithium. The lithium charge carriers may derive from a material including LiPF6 and / or LiBF4.

[0104] In some implementations, the cathodically active material may have a thickness of at least 20 microns (20pm). For example, in one implementation, the cathodically active material will have a thickness of at least 40 microns (40pm). By way of further example, in one such implementation, the cathodically active material will have a thickness of at least 60 microns (60pm). By way of further example, in one such implementation, the cathodically active material will have a thickness of at least 100 microns (100pm). In some implementations, however, the cathodically active material will have a thickness of less than 90 microns (90pm) or less than 70 microns (70pm).

[0105] Referring to the implementation shown in the example of Fig. 1 , the separator structures 105 may separate the electrode structures 102 from the counter-electrode structures 104. As indicated elsewhere, the implementation shown in the example of Fig. 2 may also include separator structures. The separator structures 105 may be made of electrically insulating but ionically permeable separator material. The separator structures 105 may be adapted to electrically isolate each member of the population of electrode structures 102 from each member of the population of counter-electrode structures 104. Each separator structure 105 may include a microporous separator material that can be permeated with a non-aqueous electrolyte; for example, in one implementation, the microporous separator material includes pores having a diameter of at least 50 angstroms (50A), more typically in the range of about 2,500 angstroms (2.500A), and a porosity in the range of about 25% to about 75%, more typically in the range of about 35-55%. The separator structure 105 may have a thickness of around 4 microns (4pm) up to around 50 microns (50pm). However, it should be appreciated that the thickness may be less than 4 microns (4pm) or greater than 50 microns (50pm) in some implementations. The separator structure material may be a microporous separator material permeated with a liquid non-aqueous electrolyte, a gel, a solid electrolyte, a polymer-based electrolyte, an oxide-based electrolyte, and / or a ceramic based separator.

[0106] The electrode busbar 108 may be a cathodic electrode busbar when the electrode structure 102 is a cathodic type and may be an anodic electrode busbar when the electrode structure 102 is an anodic type. In an example implementation, the anodic type busbar may be a copper busbar, and the cathodic type busbar may be an aluminum busbar. In other implementations, the electrode busbar 108 and the counter-electrode busbar 110 may be any suitable conductive material or materials to allow the electrode assembly 100 to function as described herein.

[0107] The electrode structures 102 and counter-electrode structures 104 may be directly connected to the electrode busbar 108 and counter-electrode busbar 110 as shown in Fig. 1 . Alternatively, as shown in Fig. 2, the electrode structures 102 and counter-electrode structures 104 may be connected to the electrode busbar 108 and counter-electrode busbar 110 via respective current limiters 206 and 207, as shown in Fig. 2. In some implementations, only the anode structures or the cathode structures may be connected via the current limiter (e.g., the electrode assembly includes either 206 or 207, but not both). In some implementations, the electrode assembly 100 and / or 200 may include a subset of either current limiters 206 and / or 207, such that some of the anode structures, some of the cathode structures, and / or some of both the anode structures and the cathode structures (but not all) are connected to the busbars 108 and 110 via current limiters 206 and / or 207. In still further implementations, two or more electrode or counter-electrode current collectors may be connected to the respective busbar via the same current limiter.

[0108] As shown in Fig. 2, each member of the population of current limiters 206 is electrically connected between a different electrode current collector 114 and the electrode busbar 108. Additionally, each member of the population of current limiters 207 is electrically connected between a different counter-electrode current collector 118 and the counterelectrode busbar 110. The current limiters 206 are configured to limit the current that may flow through the electrode current collector 114, and correspondingly through the electrode structure 102, to which it is connected. The current limiters 207 are configured to limit the current that may flow through the counter-electrode current collector 118, and correspondingly through the counter-electrode structure 104, to which it is connected. Thus, for example, if a short circuit is formed between one of the electrode current collectors 114 and one of the counter-electrode current collectors 118, the current limiters 206 and / or 207 may limit the amount of current that can flow from the other electrodes and counter electrodes of the electrode assembly and thereby limits the temperature experienced by the electrode assembly 200 and prevents a thermal runaway. Specifically, the current limiters 206 and 207 limit an amount of current that may be conducted through a unit cell during adischarge of the electrode assembly in which there is an electrical short between the electrode and counter-electrode of the unit cell to a value I, which is less than a current (sometimes referenced herein as Itr or II) through a member of the unit cell population that would induce thermal runaway of the member of the unit cell population. The current limiters provide a soft landing for the battery in the event of a short circuit. The current limiters continuously allow a non-zero level of current to flow in the event of a short circuit, but limit that current to below a level that would trigger a thermal runaway. This current will continue to flow until the battery is discharged and the risk of thermal runaway is ended.

[0109] In some implementations, the current limiters 206 and / or 207 may be resistive current limiters. The current limiters 206 and / or 207 may have a nonzero resistance within the range of normal operating temperatures of the electrode assembly 200. In one implementation, the normal operating temperatures are between negative twenty Celsius and eighty Celsius. In other implementations, the normal operating temperatures are as low as negative forty Celsius and as high as one hundred and fifty Celsius, or any other suitable range of normal operating temperatures. The resistance may be such that the current limiters 206 and / or 207 limit the current that may pass through any unit cell and prevent the current from reaching a level that may cause catastrophic failure or any other maximum current level that is determined for other performance or abuse tolerance reasons as determined during battery design. The current limiters 206 and / or 207 may not rely on a fuse or any positive temperature coefficient (PTC) characteristic of the resistive material. That is, although the current limiters 206 and / or 207 may exhibit a PTC, a PTC is not required for the current limiters 206 and / or 207 to function as described herein. Rather, the resistance of the current limiters 206 and / or 207 in the range of normal operating temperatures of the electrode assembly 200 may be sufficient to limit the current. In some implementations, the resistance may increase or decrease (i.e., the current limiters may have a negative temperature coefficient) within the normal range of operating temperatures. The current limiters 206 and / or 207 may each be electrically in series with the electrode current collector 114 or counter-electrode current collector 118 to which they are attached. Thus, the resistance of each current limiter 206 and / or 207 and its associated electrode structure 102 or counter-electrode structure 104 may be increased by adding the resistance of the associated electrode structure 102 or counter-electrode structure 104 and the resistance of the current limiter 206 or 207 attached thereto. Adding resistance to a battery is conventionally discouraged, because the added resistance will increase the losses experienced by the battery when current is flowing into the electrode structures 102 or counter-electrode structures 104 (during charging) and out of the electrode structures or counter-electrode structures (during discharge). However, because the electrode current collectors 114 and counter-electrode current collectors 118 are all connected to theelectrode busbar 108 or counter-electrode busbar 110 in parallel (electrically parallel), the increase in total resistance seen at the electrode busbar 108 or counter-electrode busbar 110 is much smaller than the resistance of each individual current limiter 206 or 207. Moreover, the resistance of the current limiters 206 and / or 207 in this disclosure is selected to be small enough to have a limited voltage drop across the current limiters 206 and / or 207 and thereby have a limited loss of power. In the example implementation, the resistance of the current limiters may be selected to have no more than a 20 mV drop across each of the current limiters 206 and / or 207 during charging or discharging at a 1 C rate to limit losses during normal operation while still protecting the battery during a short circuit.

[0110] In some implementations, such as those shown in Figs. 3A, 3B, 4A, 4B, 5, 6, and 7, the electrode structure 102 and / or counter-electrode structure 104 may be connected to the electrode busbar 108 or counter-electrode busbar 110 using an adhesive polymer. For example, as shown in Figs. 3A and 3B, an end portion 303 of the electrode structure 302, which may also be referred to as a tab of the electrode structure 302, may be bent or folded over to provide a surface area for connection to the electrode busbar 308. This is discussed in further detail below and shown in further detail in the example of Fig. 7. While the implementations shown in Figs. 3A, 3B, 4A, 4B, 5, 6, and 7 may be illustrated showing only a single electrode or single side of the battery structure (e.g., only the electrode structure connecting to the electrode busbar), the same features and functionality may also be applied with respect to the counter-electrode structure connecting to the counter-electrode busbar. In one implementation, the electrode structure is a cathode structure, and the discussion herein applies to the connection between the cathode structure and the cathode busbar.

[0111] As shown in the examples of Figs. 3A and 3B, the end portion 303 of the electrode current collector 302 is bent to approximately a ninety-degree angle. Adhesive polymer strips 320A and 320B may be applied to the end portion 303. And the electrode busbar 308 may then be positioned over the end portion 303 and affixed thereto using heat and / or pressure. The electrode busbar 308 is then attached to the end portion 303 of the electrode current collector 302 via the adhesive polymer strips 320A and 320B. While Figs. 3A and 3B illustrate a single electrode current collector 302, it should be appreciated that many electrode current collectors may be positioned next to each other and all attached to the electrode busbar 308 via the adhesive polymer strips 320A and 320B.

[0112] The adhesive polymer strips 320A and 320B may be the same material or may be different materials. In some implementations, the adhesive polymer may include a neat polymer, a thermoplastic adhesive, a thermoset, and / or a base polymer and a conductive filler. The neat polymer may be a polymer without any fibers or conductive filler. The thermoplastic adhesive may be a polymer adhesive that does not undergo any curing process or chemical reaction when being applied. Thermoplastic adhesives are typicallysolid at room temperature and can be heated to a liquid state during application. The thermoset may be a thermosetting polymer that undergoes a chemical reaction during curing, which may be an irreversible process. The base polymer and conductive filler may be any suitable polymer with a filler material suspended therein. The conductive filler material may be one or more of an aluminum filler, a titanium filler, a titanium nitride filler, a carbonbased filler, a stainless-steel filler, a noble metal filler, or mechanically agitated solders. A shape of the conductive filler may be one or more of spheres, flakes, fibers, hollow coated particles, solid coated particles, or a conductive mesh.

[0113] Selection of the adhesive polymer material and configuration (e.g., whether conductive fillers are included, and / or the material and shape of the conductive fillers), may be based at least in part on electrolyte compatibility, adhesion, and / or temperature stability. For example, certain polymers have better compatibility with the electrolyte material used in the battery, meaning that they do not degrade or change their properties as much over time. Certain polymers also provide greater adhesion to metals, plastics, or other required battery cell components. Furthermore, certain polymers exhibit reliable performance and structural integrity over the temperature range at which the battery is expected to operate. Two such polymers may include Primacor 3701 , which is an ethylene acrylic acid ionomer, and Primacor 5980I, which is an ethylene acrylic acid copolymer.

[0114] The adhesive polymer strips 320A and 320B may be an adhesive polymer, copolymer, or blend, and in some implementations may have a conductive material suspended therein. In some implementations, the adhesive polymer may be substantially nonconducting (e.g., insulating). In implementations where there are conductive fillers, the base polymer may be substantially non-conducting prior to suspension of the conductive fillers therein. Generally, desirable polymers may be any that are (a) stable in the environment of a Li-ion battery cell (i.e. do not dissolve in the electrolytes, react with electrolyte components or any other battery components, or undergo redox chemistry or reactions that degrade the material during cell operation) and (b) have melting points above the typical working temperature of a Li-ion battery. Flexibility in the polymer is another desirable trait. Therefore, materials or blends of materials with some elasticity and particularly with a glass transition temperature (Tg) above 0°C may be used. In some implementations, the polymer used for the adhesive polymer strips 320A and 320B may be a polymer blend with at least one component with a high elasticity (measured by standard methods such as modulus and / or elongation to break). In some implementations, the polymer is a flowable adhesive polymer. In such implementations, the polymer should have flow properties that allow for melt processing, including compounding of conductive aids and other additives if desired, film, foil, or sheet preparation by standard methods such as cast film, blown film, and calendaring. Melting points of the polymer(s) used for the adhesivepolymer strips 320A and 320B may allow for melt processing and bonding to the cell via a melt press or related technique and should be above the typical working temperature range of the cell. Polymers that melt from 40°C to 300°C may be used for the adhesive polymer strips 320A and 320B.

[0115] Example suitable polymers or copolymers for use in the adhesive polymer strips 320A and 320B may include EAA (ethylene-co-acrylic acid) and EMAA (ethylene-co- methacrylic acid), ionomers of the EAA or EMAA, polyethylene and copolymers thereof (such as, ethylene / 1 -octene, ethylene / 1 -hexene, ethylene / 1 -butene, and ethylene / propylene copolymers), polypropylene and copolymers thereof, a functionalized or derivatized polyethylene or polypropylene (such as, maleic anhydride grafted materials), or the like.

[0116] In some implementations, the adhesive polymer strips 320A and / or 320B may include a base polymer and a conductive filler. The conductive filler (or conductive material) suspended in the base polymer to form the conductive adhesive may be any powder, fiber, particle, or the like that confers the desired conductivity to the base polymer after compounding with the polymer. Most desirable are materials that confer the desired conductivity at lower loadings because high loading of additives may change the properties of the polymer blend in undesirable ways. For example, high loadings may lead to a significant decrease in melt processability, impacting the ability to manufacture films or sheets of conductive polymer using conventional equipment. In addition, conductive additives are often expensive materials, and lower loadings are desirable to maintain a lower cost for manufacturing.

[0117] As noted above, the conductive filler material may be one or more of aluminum, titanium, titanium nitride, carbon-based materials, stainless steel, a noble metal, or mechanically agitated solders. Other suitable materials may include, for example, conductive carbon black, metal coated carbon fiber, carbon nanotubes, nickel, copper, gold, silver, tin, titanium, graphite, molybdenum, platinum, chromium, aluminum, or any other metallic particles, including alloys or blends thereof. Loading of conductive material into the polymer to form the adhesive polymer strips may be in the range of 1% to 50% conductive material (as weight percent of the total mixture), between 2% to 40%, or between 3% to 30%. The coated fibers may include an elemental metal and / or a metal alloy. In an example, the carbon fibers are coated with Nickel.

[0118] As shown in Figs. 3B, 4A, 5, and 6, the adhesive polymer strips 320A and 320B may be positioned such that they extend along the length L of the electrode assembly 300 in the stacking direction. In some implementations, such as are shown in Figs. 5 and 6, the adhesive polymer strips 320A and 320B may be positioned at the edges of the end portions 303 in the height (H) direction (e.g., along the outer edges of the end portions 303). In other implementations, such as are shown in Figs. 3A, 3B, and 4A, the adhesive polymer strips320A and 320B may be positioned inset from the edges of the end portions 303 in the height (H) direction.

[0119] In some implementations, each adhesive polymer strip may extend the full length of the electrode assembly 300 in the stacking direction (L). In other implementations, each adhesive polymer strip may extend in the stacking direction only as far as to match the length of the end potions 303 of the electrode assembly. In some implementations, each adhesive polymer strip may be slightly longer than the electrode assembly in the stacking direction (L), such as in Figs. 4A and 4B. In some implementations, one or more of the adhesive polymer strips may extend only partially along the length of the electrode assembly in the stacking direction (L). In some implementations, two or more of the adhesive polymer strips may be offset from each other. These offset strips, when combined, may extend the full length of the electrode assembly in the stacking direction (L). For instance, a first strip may extend from a first end of the electrode assembly in the stacking direction L to a halfway point of the assembly. A second strip, offset from the first strip in the height direction (H) (e.g., either closer to or farther from the edge of the end portion 303) may extend from the halfway point to a second end of the electrode assembly. When combined, the first strip and the second strip provide full coverage of the electrode assembly in the stacking direction (L). The electrode assembly is encased in a casing comprising a first constraint 501a and its opposing constraint 501b, and two opposing end plates such as 502. Cells are stacked within the casing, e.g., cell 503.

[0120] In the illustrated implementations, the electrode assembly 300 may include two adhesive polymer strips, each extending in the stacking direction (L), and spaced apart from each other in the height direction (H). In other implementations, there may be a single adhesive polymer strip, or there may be three or more adhesive polymer strips. For examples where there are two or more adhesive polymer strips, they may be spaced apart in the direction of height (H) such that there is no overlap, or they may be positioned such that there is some overlap. Additionally, the adhesive polymer strips may be positioned such that they are parallel to each other or may be at an angle with respect to each other. Further, the adhesive polymer strips may be positioned such that they are parallel to the stacking direction (L) or are at an angle with respect to the stacking direction (L). It should be appreciated that the adhesive polymer strips may be positioned with any suitable configuration or combination of strip placement, length, orientation, and coverage of the end portions of the electrode current collectors, (n the illustrated implementations, the thickness of the adhesive polymer strips in the height direction (H) may be approximately 10% of the height of the electrode assembly. However, it should be appreciated that the thickness may be any suitable thickness that is smaller or larger than 10% of the height of the electrode assembly. In some examples, the thickness of the adhesive polymer may be approximately100 microns (100pm), while in other examples the thickness may be as low as 2 microns (2pm), or as high as 500 microns (500pm) or more. The thickness may depend on one or more factors, such as material cost, pressure required during application, resulting mechanical and / or electrical connection quality, and more.

[0121] In some implementations, in addition to the adhesive polymer strips 320A and 320B, the end portions 303 of the electrode structures 302 may be affixed to the electrode busbar 308 via welding. Example Fig. 6 illustrates that there may be adhesive polymer strips 320A and 320B positioned at the edges of the end portions 303, and there may be welds 330 positioned at the middle of the end portions 303 connecting the end portions 303 to the electrode busbar 308. In some implementations, the welding 330 may be continuous along the length of the electrode busbar 308 in the stacking direction (L), while in other implementations, the welding 330 may be only in certain spots, or some other discontinuous pattern. Furthermore, the welding 330 may be positioned along the center line of the electrode busbar 308 (as shown in Fig. 6) or may be positioned offset to one side or the other in the height direction (H). Additionally, there may be one, two, or more welding lines, which may be spaced apart from each other, and / or may mirror the positioning of the adhesive polymer strips 320A and 320B.

[0122] FIG .7 illustrates enlarged side views of the end portions 303 of a plurality of electrode structures, before the adhesive polymer strips or the electrode busbar have been applied. As illustrated, first and second subsets of the end potions 303 are folded over or bent in opposite directions toward each other. Alternatively, in some implementations, each end potion 303 may be bent in the same direction, as illustrated in example Fig. 4B where each end portion is bent to the left.

[0123] The implementations illustrated in example Figs. 3A, 3B, 4A, 4B, 5, 6, and 7 each include the electrode structures connected to the electrode busbar without a current limiter positioned in between. However, in some implementations, the end portions of the electrode structures may act as current limiters, may be made from the material of the current limiters described herein, and / or may be connected to current limiters. In these cases, the current limiters may be affixed to the electrode busbar via the adhesive polymer strips in a manner similar or identical to that described herein. For instance, the descriptions herein that refer to affixing the end portions of the electrode structures to the electrode busbar via the adhesive polymer strips may instead be understood as referring to affixing the current limiters to the electrode busbar via the adhesive polymer strips, wherein the current limiters are also affixed to the end portions of the electrode structures.

[0124] Fig. 8 is an example flowchart of an illustrative process 800 for affixing an electrode busbar to the end portions of a plurality of electrode structures, in accordance with some implementations of the disclosure. Process 800 may be illustrative of the techniques thatmay be carried out by an assembly or manufacturing system for secondary batteries described herein. Although the processes are illustrated and described as a sequence of actions, it is contemplated that various implementations of the process may be performed in any order or combination, need not include all the illustrated actions, and / or may include additional actions not shown in Fig. 8. At 802, the process of affixing the electrode busbar to the electrode structure begins. At 804, the process 800 includes stacking the electrode structures in the stacking direction. As illustrated with respect to Figs. 1-7, the electrode structures may be arranged in an interdigitated structure, wherein the electrode structures and counter-electrode structures are stacked in an alternating manner. The electrode structures and counter-electrode structures may be oriented such that end portions of each structure extend outward in the width direction (W), as illustrated in Figs. 1-6. At 806, the process 800 includes folding over the end portions of the electrode structures. The end portions may extend outward in the width direction (W) and may be folded over such that they overlap each other, as shown in Fig. 7. In some implementations, each of the end portions may be folded over in the same direction (e.g., as shown in Fig. 4B). In other implementations, the end portions may be folded over toward a middle of the battery structure (e.g., as shown in Fig. 7). In still other implementations, the end portions may be folded over away from the middle of the battery structure, and / or subsets of the end portions may be folded in different directions (e.g., toward the middle, away from the middle, or the like). At 808, the process 800 includes applying the first adhesive polymer strip and the second adhesive polymer strip to the electrode busbar. As noted above, the adhesive polymer strips may be thermoplastic, thermoset, and / or may be a neat polymer or a base polymer with conductive filler suspended therein. Process 800 may also include heating the adhesive polymer to allow the polymer to flow during application. In some implementations, rather applying the adhesive polymer to the electrode busbar, the process may instead include applying the adhesive polymer to the end portions of the electrode structures. At 810, the process 800 includes positioning the electrode busbar next to the end portions of the electrode structures. This may include aligning the electrode busbar with the end portions of the electrode structures, as shown in Figs. 3B, 4A, 4B, 5, and 6. At 812, the process 800 includes applying pressure to the electrode busbar to affix the electrode busbar to the end portions of the electrode structures via the first and second adhesive polymer strips. In some implementations, the pressure is applied uniformly to the surface of the electrode busbar. The pressure forcing the electrode busbar into the end portions of the electrode structures causes the adhesive polymer strips to compress, thereby increasing the contact surface with the end portions of electrode structures and the electrode busbar. Additionally, the pressure may cause the adhesive polymer strips to expand sideways in the height (H) direction, thereby increasing the contact area between the end portions of theelectrode structures, the adhesive polymer strips, and the electrode busbar. Furthermore, in some implementations, the pressure on the electrode busbar may cause the adhesive polymer to expand outward toward the outer edges of the end portions in height (H) direction, as well as to expand inward toward a center of the end portions.

[0125] In some implementations, the pressure may be applied to a middle of the electrode busbar in the height (H) direction, such that the pressure is applied in a line extending in the stacking direction (L) between the adhesive polymer strips. This non-uniform pressure may cause a deflection of the middle portion of electrode busbar, such that the outer edges of the electrode busbar that are positioned over the adhesive polymer strip may deflect upward, while the middle portion receiving the pressure bends down to contact the end portions of electrode structures. This may reduce the amount of adhesive polymer that expands sideways or oozes out from between the electrode busbar and the end portions of the electrode structures. The process 800 may then end at 814.

[0126] In some implementations, the process 800 may also include welding the electrode busbar to the end portions of the electrode structures. Fig. 6, illustrates an implementation wherein the centerline of the electrode busbar along the stacking direction (L) is welded to the end portions of the electrode structures. In other implementations, the welding may be performed along a different line, in a different shape, or in a different orientation with respect to the electrode busbar.

[0127] 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. 14, 1431) of the face to a height (e.g., Fig. 14, 1432) of that face. The cell may have an aspect ratio of at least 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. 14, 1432) of the cell to a width (e.g., Fig. 14, 1404, showing a width of three cells).

[0128] In some embodiments, a battery cell comprises an electrode (e.g., reference electrode), a counter electrode, and 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 such as a dynamic 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 dividingspace. The dividing space and the separating space may or may not have the same material content.

[0129] Fig. 9 shows in example 900 a schematic representation of a battery cell, the battery cell comprising an electrode 902a - “C” (e.g., a cathode), and an opposing electrode which is a counter electrode 905a - “A” (e.g., an anode). A separator is disposed in separator space 903 - "B.” The battery cell is disposed in a battery having housing 909. 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 904. 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 (ZnOz), 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 906 passing from one electrode to its opposing electrode, and through separation space 903. When volume 904 comprises the insulator, the insulator contacts at least at opposing sides 902b and 902c of electrode 902a and at opposing sides 2905b and 905c of counter-electrode 905a.

[0130] Fig. 9 shows in example 910 a schematic representation of a battery cell, the battery cell comprising an electrode 912 - “C” (e.g., a cathode), and an opposing electrode which is a counter electrode 915 - “A” (e.g., an anode). A separator is disposed in separator space 913 - “B." The battery cell is disposed in a battery having housing 919. The separation space extends 921 beyond electrode 912, and extends 922 beyond counter electrode 915, the extension being along a long axis of each of the electrode, the long axis depicted in Fig. 9. The extension can extend longer in the lateral direction. The extension can form the tab. The battery has an insulator 914. Under the normal conditions, the load current 916 may be passing through separation space 913.

[0131] 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, 9, 920 for a cell. The cell can comprise at least one uneven side, e.g., as is depicted in Fig. 9, 920. The uneven (e.g., misaligned) side can create a wavy side of a set of cells.

[0132] Fig. 10 shows in example 1050, 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 1051 , battery cells are arranged parallel to each other. Examples 1052-1055 show various folding of a sheet comprising one or more battery cells,with 1052 showing a zigzag fold, 1053 showing a top hat fold, 1054 showing a sinusoidal type fold, 1055 showing a spiral (e.g., rolling) fold, and 1056 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. 21, 2150.

[0133] Fig. 10 shows a schematic example 1000 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, 1 m, 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 0.1 mm. 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 1001 , and 1002. The current collector has a length 1003, a width 1004, and a height 1005. Section 1002 designates the tab of the current collector that will bend upon assembly of the energy storage device, and section 1001 designates the planar section of the current collector. In the example shown in 1000, the tabs assume the same width 1004 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 1011 of the current collector, the current collector having a shorter axis 1012 normal to axis 1011. The contraction of the tabs along axis 1011 may be symmetrical about axis 1011, e.g., using a mirror symmetry, the mirror being along axis 1011.

[0134] In some embodiments, one or more cells are disposed within a housing to form the battery. The housing may insulate the battery from one or more reactive agents in the ambient environment external to the battery. The reactive agent(s) may comprise oxygen, water, alcohol, thiol, sulfuric acid, phosphoric acid, carboxylic acid, or hydrogen sulfide. The reactive agent(s) may be oxygen based, sulfur based, and / or phosphorous based. The reactive agent(s) may comprise water or oxygen. In an example, the reactive agent(s) comprise water in a liquid and / or vapor form. The water may be in a droplet form. The housing may be configured to insulate the cell(s) from the reactive agent(s) present in the ambient environment external to the battery, e.g., to curtail (e.g., hinder, or prevent) reactive agent(s) from reaching the cell such as including reaching the electrode(s).

[0135] In some embodiments, the battery is a prismatic battery. The prismatic battery may have a height (e.g., Fig. 10, 1005) of at least about 1mm, 2mm, 3mm, 5mm, 6mm, or 8 millimeters (mm). The prismatic battery may have a length (e.g., Fig. 10, 1003) of at least about at least about 10, 50, or 100 millimeters.

[0136] Fig. 11 shows schematic perspective view examples of batteries and battery cell architecture therein relative to a Cartesian coordinate system. Example 1100 shows a cylindrical battery housing having a length 1102 and height 1101 , which is a diameter. The battery may comprise cell(s) that form a rolled sheet. In example 1100, 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 113110 shows a prismatic battery housing that is a rectangular prism, or a cuboid. The battery has length 1132, height 1131 , and width 1133. Battery cells 115 are stacked in the battery along height 1131 , and along the Z direction. In example 1130, face XY has a larger surface area than face XZ, and face XY has a larger surface area than face YZ. Example 1150 shows a prismatic battery housing that is a rectangular prism, or a cuboid. The battery has length 1152, height 1151, and width 1153. Battery cells 1155 are stacked in the battery along length 1152, and along the X direction. In example 1150, face XY has a larger surface area than face XZ, and face XY has a larger surface area than face YZ.

[0137] 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. Fig. 11, 1150 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 1150, 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. 11 , 1150), 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. 11 , 1130) and / or to (b) cylindrical battery such as a wound cell (e.g., jelly roll) battery (e.g., Fig. 11 , 1100). 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. 9, 920, 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.

[0138] In some embodiments, the 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 insulator may or maynot comprise the dynamic insulator. The dividing space may be configured to electrically separate one cell from another. The battery stacks 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. 12. The battery 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 1290 in Fig. 12). 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. 9, 920. See also sides (e.g., edges) of cell sets in Fig. 12, 1200, and 1250. 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.

[0139] Fig. 12 shows a schematic cross-sectional example 1200 of a battery comprising cathode 1202, anode 1205, separation space 1206, and dividing space 1207. The battery cells are disposed in volume 1204 of the battery that can include an insulator such as a dynamic insulator. The battery cells are stacked along an axis 1290, in a repeating CBAS arrangement. Each anode “A" in the battery is operatively coupled (e.g., connected) with a current collector such as 1213, the anode current collectors being coupled in parallel to a main anode current collector 1214, ending with cathode contact 1211. Each cathode "C” in the battery is operatively coupled (e.g., connected) with a current collector such as 1216, the anode current collectors being coupled in parallel to a main cathode current collector 1217, ending with anode contact 1212.

[0140] Fig. 12 shows a schematic cross-sectional example 1250 of a battery comprising cathode 1252, anode 1255, separation space 1256, and dividing space 1257. The battery cells are disposed in volume 1254 of the battery that can include an insulator such as a dynamic insulator. The battery cells are stacked along an axis 1290, in a repeating CBASABCS arrangement. Each anode "A” in the battery is operatively coupled (e.g., connected) with a current collector such as 1263, the anode current collectors being coupled in parallel to a main anode current collector 1264, ending with cathode contact 1261 . Each cathode “C” in the battery is operatively coupled (e.g., connected) with a current collector such as 1266, the anode current collectors being coupled in parallel to a main cathode current collector 1267, ending with anode contact 1262. In Fig. 12, the main cathode current collector is disposed on a different face of the set of cells as the main anode current collector, which is the opposing face.

[0141] In some embodiments, the battery comprises main current collectors, e.g., as disclosed herein. The main current collectors may or may not contact the insulator covering the edges of the cells. In the example shown in Fig. 12, 1200, the main current collectors 1217 and 1214, are separated from the insulator 1204 by a gap. In the example shown in 1200, the main current collectors 1217 and 1214 contact the insulator 1204.

[0142] 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. 12, 1290). Fig. 12, 1200 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 1220 contacting the insulator at its opposing lateral ends. Fig. 12, 1250 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 1290.

[0143] 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 twocells 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 symbol “*” designates the mathematic operation of multiplication.

[0144] 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 device during the charge / discharge operations. The constraint may be configured to maintain internal pressure in the device, e.g., during the charge / discharge operations. The internal overpressure in the device may be at most about 100PSI, 150PSI, 200PSI, 500PSI, 1000 PSI, 2000 PSI, 3000 PSI, 5000PSI, or 10000PSI. The internal overpressure in the device may be at most about 50 PSI, 100PSI, 150PSI, 200PSI, 500PSI, 1000 PSI, 2000 PSI, 3000 PSI, or 5000PSL The internal overpressure in the 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 device may be greater than the ambient pressure external to the 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 device. Substantial reversal of the face’s deformation may be within the specification and / or intended use of the device.

[0145] In some embodiments, the battery cell set is disposed in an orthogonal stacked configuration. %%

[0146] Fig. 13 shows in example 1300 an exploded view of a pair of constraints 1301a and 1301b encasing a set (e.g., a population) of stacked battery cells 1302. Example 1350 shows an exploded view in which the two constraints 1301a-b are closer to the stacked cell set 1302. Fig. 13 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. 13, the constraint can deter expansion of the cells anisotropically along the Y axis.

[0147] Fig. 14 shows in example 1400 a lateral portion of three cells, each comprising an electrode such as 1401, a counter electrode such as 1403, and a separator 1402 disposed between each immediately adjacent pair of electrode and counter electrode. In example 1400, the electrode (E.g., 1401) extends less than the counter electrode 1403 to the lateral edge 1404 of the stacked cells, with the separator extending more towards the edge than the electrode, and than the counter-electrode, e.g., thus forming a corrugated, or wavey, lateral edge 1404. Example 1430 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.

[0148] Example 1450 shows a set of stacked cells 1451 enclosed by two opposing casings 1452a and 1452b. Current collectors of the stacked cells are coupled with connectors 1453a and 1453b. 1453a connect to the electrodes of the set of cells, and 1453b connects to the counter-electrodes of the set of cells. The cells enclosed by the casings (e.g., housing or case), are further secured by a flexible material 1455, 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. 14, casing 1452a includes oblong openings, e.g., that are evenly spaced along the X direction. Fig. 14 is shown with respect to a Cartesian coordinate system.

[0149] Fig. 15 shows in example 1500 an exploded view of a pair of constraints 1501a and 1501b encasing a set (e.g., a population) of stacked battery cells 1502. Each of constraints 1501a-b includes oblong openings, e.g., that are evenly spaced along the X direction. Fig.15 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.

[0150] Example 1530b is a microscope image of section 1530a. The image shows a set of cells comprising (a) anodes including (i) anode active material such as 1531 and (ii) anode current collector such as anode current collector 1532; (b) anodes including (iii) anode active material such as 1533 and (iv) cathode current collector such as cathode current collector 1534; (c) separators such as separators 1535 and 1536; and (d) insulating material such as1537. Each cathode is separated from its immediately adjacent anode by a gap, the separator disposed in the gap. In the example shown in 1530, 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 1535 and 1536 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 1530b, (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 1530b, (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.

[0151] Example 1560b is a microscope image of section 1560a. The image shows a set of cells comprising (a) anodes including (i) anode active material such as 1561 and (ii) anode current collector such as anode current collector 1562; (b) anodes including (iii) anode active material such as 1563 and (iv) cathode current collector such as cathode current collector 1564; (c) separators such as separator 1565. Each cathode is separated from its immediately adjacent anode by a gap, the separator disposed in the gap. In the example shown in 1560, 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 1567, to form a busbar. In the example shown in Fig. 15, 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.

[0152] In some embodiments, the electrode comprises a current collector extending beyond the section contacting the electrode active material. The electrode current collector may extend beyond the largest surface area of the electrode to one side, and the counterelectrode current collector may extend beyond the largest surface area of the counterelectrode to an opposing side to the one side. At least one of (a) the electrode current collectors and (b) the counter-electrode current collectors, may be disposed in a respective case. The case may be open at least one face, e.g., at its opposing faces. In an example, the electrode current collectors may be disposed in an electrode case. In an example, the counter-electrode current collectors may be disposed in a counter-electrode case. In an example, the electrode case and counter-electrode case is the same case. In an example, the electrode case and counter-electrode case are different cases. The cells may be held by at least one constraint, e.g., two constraints facing each other. The exposed face of the first cell may be covered by a first end plate and / or the exposed face of the last cell may be covered by a second end plate. The cells may be held by one or more endplates. The case may include the constraint(s) and / or end plate(s). In an example, the case may be formed by the two opposing constraints and the two opposing face plates. Vertical cross sections of the two opposing constraints may form the longer sides of the case, and vertical cross sections of the two opposing end plates may form the shorter sides of the case. A vertical cross section of the case may comprise the vertical cross sections of the two opposing constraints. The folded tabs may be disposed in the space bordered by the end plates and by the constraints. The tab case may be open in at least one face accommodating the largest face of the current collectors end portion (also referred to herein as “tabs”), e.g., such that a largest face of the tab is exposed. In an example, the cathode tab case is open such that the top face of the cathode current collector tabs is exposed, e.g., the cathode tab case face may be at the face type of the case having the larges surface area. In an example, the cathode tab case is open such that the top face and the bottom face of the cathode current collector tabs is exposed, e.g., the cathode tab case face may be at the face type (e.g., top face and / or bottom face) of the case having the larges surface area. The case body may comprise the conductive material, e.g., comprising one or more of elemental metal, metal alloy, or the allotrope of elemental metal. The case may comprise a composite, or a noncomposite material. The case may be open at one or more of its opposing faces, e.g., its top and / or its bottom. At least one of (a) the electrode current collector and (b) the counterelectrode current collector, may comprise a D-slot. At least one of (a) the electrode current collector and (b) the counter-electrode current collector, may be devoid of the D-slot, and / or devoid of a busbar connecting the current connector of a respective electrode through the D- slot, e.g., as an internal skeleton to the tabs. The case may comprise elemental metal, metal alloy, or an allotrope of elemental carbon. In an example, the case comprises stainless steel, copper, or aluminum. In an example, the case comprises one or more of stainless steel, copper, and aluminum. The case may be (e.g., substantially) of the same type of material from which the tabs are made of, the case encasing the tabs. The connection of the current connectors may comprise forming an electrical contact between the current connectors.Formation of the electrical contact may comprise one or more of welding, sintering, or adding a tacky connector, e.g., an adhesive such as an adhesive polymer. The tacky connector may or may not be conductive. The tacky connector may or may not comprise a material that is non-electrically conductive. The tacky connector may or may not comprise a material that is electrically conductive. The tacky connector may serve to connect a (e.g., solid) busbar to electrode current connectors. The tacky connector may serve to connect electrode current connectors to form a busbar. In an example, welding and adding the tacky connector is utilized to electrically connect the tabs of a population of cells, e.g. a set of cells. The tacky connector may comprise a polymer or a resin. The tacky connector may comprise ethylene acrylic acid ionomer (e.g., as disclosed herein), or a polyimide. The tacky connector may be of (e.g., substantially) the same type of material used in other section(s) of the energy storage device, e.g., constraint adhesive. The tacky connector is configured to be compatible with the chemistry and normal operation of the cell. Normal operation of the cell comprises operation of the cell at prescribed conditions, e.g., according to the specification of the device. During manufacturing, the tacky material may be deposited on the tabs in its hot state. The tacky connector may comprise two or more tacky connector materials. The two or more tacky connector materials may be of the same group of materials or of different groups or material. In an example, the tacky connector comprises two or more polymers. In an example, the tacky connector comprises a polymer and a resin. In an example, the tacky connector comprises a polymer and a conductive filler (e.g., powder). The conductive filler may be configured to remain solid at the melting point of the non-filler (e.g., non-pulverous) material type comprises in the tacky connector. The conductive filler may comprise elemental metal, metal alloy, or an allotrope of elemental carbon. The conductive filler may include aluminum, titanium, an allotrope of elemental carbon, and / or Titanium Nitride (TiN). The filler may assume one or more shape. The one or more shape may include spheres, cubes, fibers, flakes and / or amorphous shapes. The allotrope of elemental carbon may comprise graphite, amorphous carbon, carbon fibers, carbon nanotubes, or fullerenes. The tacky connector may include a thermoplastic, and / or a thermoset. The tacky connector may comprise Kapton, e.g., a polyimide tape. The tacky connector may comprise a conductive material dispersed in the tacky connector. The conductive material may comprise an elemental metal, a metal alloy, or an allotrope of elemental metal. The conductive material of the tacky connector may comprise a particulate material, a tubular material, or threads. The tacky connector may be the adhesive polymer disclosed herein. The tacky connector may be flowable applied, e.g., as a flowable mass such as a slurry, a liquid, or liquidous, mass. The tacky connector may be sprayed or deposited onto the tabs. The tacky connector may be applied as a strip, e.g., a tape, connecting the tabs. In an example, the tacky connector is applied on the exposed surface of the tabs. The tacky connector may form a strip or a tape,e.g., upon hardening. The tacky connector may assume a harder consistency as compared to the more flowable consistency upon its application. The harder consistency may be solid or semisolid. The harder consistency may be flexible such that it allows (e.g., reversible) extension and contraction upon charging and recharging of the cell. 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 connection of the current connectors with the busbar may be configured to allow the cell volume to reversibly change between the state of charge and the state of discharge repeatedly. The tacky connector may have a component that is fluid upon application, e.g., that can flow on the side of the tabs. The tacky connector can be configured to flow by heat and / or application of mechanical pressure, e.g., to connect tabs to themselves, and / or to an additional busbar such as without an addition of a conductive fillers.

[0153] In some embodiments, using one electrical connecting methodology is insufficient to secure electrical connection of the tabs during the repeated charge and discharge operations. In an example, the tacky material - when used as the only electrical connector of the tabs - may separate from the current connector tabs during the charge and discharge operations. In an example, the welding - when used as the only electrical connector of the tabs - may break during the charge and discharge operations. Use of several electrical connection methodologies may solve such hardship(s). Use of several electrical connection methodologies may increase the reliability, durability, and strength, of the electrical connection between the tabs.

[0154] In some embodiments, the battery comprises a set of cells, also referred to herein as “a population of cells.” The set of cells may comprise at least 10, 20, 50, 100, 150, 200, 250, or 500 cells.

[0155] In some embodiments, the current collector comprises a face type having the largest surface area. That face type may comprise an internal portion and a bent portion with respect to the internal portion. The internal portion being internal to the stacked cells relative to the tab. The internal portion may have a surface area larger than that of the bent portion - the tab. The tab may be bent in one or more directions. In an example, the tab may be bent such that it forms an angle alpha of at most 100 degrees (°) with respect to the internal portion of the current collector. The angle alpha can be at most about 160°, 140°, 120°, 100°, 95° or 90°, with respect to the internal portion of the current collector, the angle being the smallest angle. The angle alpha can be at least about 140°, 120°, 100°, 95° or 91 .5°,, with respect to the internal portion of the current collector, the angle being the smallest angle. The angle alpha can be of a value between any of the aforementioned values, e.g., from about 90° to about 160°, or from about 90° to about 120°, with respect to the internal portion of the current collector, the angle being the smallest angle. The bent area where thetab portion contacts the internal portion of the current connector, may be bent sharply, or bent gradually. A horizontal cross section of the connecting section between the tab and the internal portion of the current collector, may form a line or an area. The gradual bending of the tab with respect to the internal portion of the current collector, may form a curvature. The curvature may reduce breakage (e.g., due to fatigue) of the tab with respect to the internal portion at their connecting section. A vertical cross section of the tab may be a line, e.g., a straight line. The tab may comprise a flexible portion that will allow the tabs to be operatively coupled (e.g., electrically connected) during the charge and discharge cycles of the device. The flexible portion can be similar to a mechanical spring. The flexible portion may comprise sliding portions with respect to each other, that are electrically connected, e.g., using the tacky connector. A vertical cross section of the tab may comprise an alternating shape. The alternating shape may comprise a sinusoidal, or a zigzag shape. The alternating cross sectional shape may comprise an “S,” a “Z,” or a “LT” shape. In an example, the alternating shape comprises a Z fold. Along the propagation of the fold, the alternating cross-sectional shape can have the same amplitude along propagation of a changing amplitude. The alternating cross sectional shape can have a diminishing amplitude and / or an increasing amplitude. The diminishing amplitude may change (e.g., diminish) towards a distal end of the tab. Along the propagation of the fold, the alternating cross-sectional shape can have the same pitch along propagation of a changing pitch. The alternating cross sectional shape can have a diminishing pitch, and / or an expanding pitch. The diminishing pitch may change (e.g., diminish) towards a distal end of the tab. The alternating portion of the tab may be disposed close to the connection of the tab with the internal portion of the current connector. The alternating portion of the tab may contact the internal portion of the current connector and / or a planar section of the tab. The alternating portion of the tab may be configured to function as a spring, e.g., during the expansion and contraction of the cell occurring during the charge and discharge phases of the device. The alternative shape may alternate across a median line of the tab, the median line propagating from a first end of the internal portion of a current collector towards a second end of the tab of the current collector, which opposes the first end, the median line being equidistant to the two sides of the tab, the equidistant being normal to the median line. An example of a median line of the current collector is in Fig. 1 , 1011. Fig. 1 shows an example of a long axis of a face of the current collector comprising the height (e.g., thickness) of the current collector. The alternating section of the tab may propagate along the median line. The median line may be disposed at a center of the height of the current collectors, e.g., the median line may intersect position 1014.

[0156] Fig. 1 shows in example 1070 various fold types of the current collector, with line “A” representing the median line of the current collector. Examples 1071a-1073a and 1071b- 1073b show various alternating folds of at least a section of the tab. 1071a and 1071b depicta zigzag fold, 1072a and 1072b depict a top hat fold, and 1073a and 1073b depicts a sinusoidal fold. Folds 1071a, 1072a, and 1073a have an amplitude that remains (e.g., substantially) constant along median line A. Folds 1071b, 1072b, and 1073b have an amplitude diminishes along median line A. In example 1070, the pitch of the alternating cross-sectional shape remains (e.g., substantially) constant. In other embodiments, the pitch may alter (e.g., increase or decrease) with the propagation of the fold, e.g., relative to the distance of the fold from the exposed end of the tab.

[0157] The electrode current collector may extend beyond the largest surface area of the electrode to one side, and the counter-electrode current collector may extend beyond the largest surface area of the counter electrode to an opposing side to the one side. In some embodiments, the current collector comprises a face type having the largest surface area. That face type may comprise an internal portion and a bent portion with respect to the internal portion. The internal portion may have a surface area larger than that of the bent portion - the tab. The tab may comprise an indent. The indent may extend from an end of the tab farthest from the internal portion, towards the connecting area of the tab with the internal portion. The indent may divide the tab laterally into (e.g., substantially) equal sections at the largest surface area face of the tab. The tab may be disposed in the lateral middle of the largest surface area face of the tab. In an embodiment, a first portion of each of the tabs disposed closer to a side of the case bends in a direction (e.g., forward), and a second portion of each of the tabs further away from the side bends in an opposite direction (e.g., backwards). The tabs may be divided into a first set of tabs and to a second set of tabs. The tabs in a case (e.g., regardless of the indent) may be bent towards one or more directions. In an example, a first set of tabs bend towards a first direction, and a second set of tabs bend towards a second direction opposing the first direction. The first set may contact the second set, e.g., at their meeting point. At least one tab may be disposed between the bent table of the first sent and of the second set. The at least one tab may assume a bending direction of the first set, of the second set, or another bending direction, e.g., the at least one tab may be curled, folded, or otherwise wrinkled. The indent may be utilized for connecting the tabs, e.g., for welding and / or for administering the tacky connector. The tabs in a case may be bent towards one or more directions. In an example, a first set of tabs may be bent towards a first direction, and a second set of tabs may be bent towards a second direction opposing the first direction. The first set may contact the second set, e.g., at their meeting point. At least one tab may be disposed between the bent table of the first sent and of the second set. The at least one tab may assume a bending direction of the first set, of the second set, or another bending direction, e.g., the at least one tab may be curled, folded, or otherwise wrinkled. In an example, the first set contacts the second set. In an example, at least one tab of the first set is folded onto at least one tab of the second set,e.g., in an area where the sets contact each other. In an example, the first set of tabs, (A) a first portion of each of the tabs disposed closer to a side of the case, are bent in a direction (e.g., forward); and (B) a second portion of the tabs further away from the side, are bent in an opposite direction (e.g., backwards). In an example, in the second set of tabs, (a) a first portion of each of the tabs disposed closer to a side of the case are bent in the opposite direction (e.g., backwards), and a second portion of the tabs further away from the side are bent in the direction (e.g., forwards).

[0158] In some embodiments, the tab may be devoid of an indent. In some embodiments, the tab comprises a plane, e.g., a planar plane such as a flat plane. The tabs of the cells in the plurality of cells may be disposed in the case, e.g., the case disclosed herein. At least two of the tabs may lie one on top of each other. At least two of the tabs may contact each other. At least two of the tabs may be bent in the same directions. The tabs in a case may be bent towards one or more directions. In an example, a first set of tabs may be bent towards a first direction, and a second set of tabs may be bent towards a second direction opposing the first direction. The first set may contact the second set, e.g., at their meeting point. At least one tab may be disposed between the bent table of the first sent and of the second set. The at least one tab may assume a bending direction of the first set, of the second set, or another bending direction, e.g., the at least one tab may be curled, folded, or otherwise wrinkled. In an example, the first set contacts the second set. In an example, at least one tab of the first set is folded onto at least one tab of the second set, e.g., in an area where the sets contact each other.

[0159] Fig. 16 shows schematic example 1630 depicting an edge portions of an energy storage device, e.g., a battery. The device comprises battery cells including alternating structure of electrodes such 1601 and counter electrodes separated from each other by a gap such as 1632, 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 1633. The tab of current collectors of an electrode type, extend to the same lateral direction beyond an edge of the separator, which separator extends laterally beyond each of the electrode types. The set of cells is encased in a casing formed by two opposing casings 1637a and 1637b, and by two opposing end plates such as end plate 1638.

[0160] Example 1600 shows a microscope image of a side face of a portion of set of cells having cells such as 1601 . Tabs of one electrode type (e.g., either anode or cathode) extend beyond the edge of the cells. Tab examples are 1602a and 1602b. The tabs of the electrode type are divided into two groups (e.g., two sets or two populations) that are folded towardseach other, the two groups of tabs being 1603 and 1604 respectively. The direction of folding is schematically depicted by respective white arrows that point towards the folding direction.

[0161] Example 1660 shows a microscope image of an edge portion of a set of cells similar to the one shown in example 1600 that underwent further processing. In example 1660, the edge with the folded tabs 1662 and the edges of the cells devoid of the tabs such as 1661, are covered with a tacky material that operatively (e.g., electrically) connects the tabs of one electrode type, to collectively form a busbar. The tacky connector may or may not include perforations (e.g., holes).

[0162] Example 1680 shows a microscope image of an edge portion of a set of cells similar to the one shown in example 1600 that underwent further processing. In example 1680, the edge with the folded tabs and the edges of the cells devoid of the tabs, are covered with a conducive material 1681 (including copper) that operatively (e.g., electrically) connects the tabs of one electrode type, to collectively form a busbar. The tacky material section (e.g., strip) comprises holes such as hole 1682. The holes are arranged in triplets normal to a stacking direction of the cells, and the triplets align along the stacking direction, the triplets being evenly spaced along the stacking directions, the holes of the triplet being evenly spaced and centered about the stacking axis of the cells.

[0163] Fig. 17 shows in 1700 microscope image example of an edge of stacked cells having tabs of one electrode type that were welded and that include the tacky connector, e.g., adhesive polymer. Most of the tabs were removed (e.g., ripped), except for tab 1707. An example of a cell is 1703. The weld was effectuated by a laser, e.g., in area 1701. The laser had a power such that the weld did not (e.g., substantially) affect the function of, and / or otherwise damage, the separator disposed between two immediately adjacent electrode and counter electrode in the set of cells. An example of a tacky connector can be seen in 1702. The tacky connector can be applied as a fluid hotter mass, which may be later cooled. The tacky connector can be inconsistently heated, e.g., and for an inconsistent bond between the current connectors in the edge of the stacked cells. 1706 shows a planar edge of the current collector on the side of the tab. The tabs may be referred herein as “iTabs."

[0164] Example 1750 shows a microscope image of an edge of stacked cells having tabs of one electrode type that are welded and that includes a tacky connector. Examples of cells are 1751 and 1754. An example tab of the electrode current collector is 1752. Tacky connector is disposed on the welded tabs, the tacky connector having perforations (e.g., holes) arranged in triplets stacked along the stacking direction, in an arrangement similar to the one described in example 1680. An example of a perforation is 1753. Example 1750 is an image taken after a solid busbar was removed, e.g., to inspect the weld underneath. 1755 shows an area of an overflow of the tacky connector (adhesive) potentially interfering withthe weld. In some instances, it may be beneficial to minimize such overflow of the tacky connector.

[0165] Fig. 18 shows in example 1800 a microscope image of an edge of stacked cells having tabs of one electrode type that are welded and that includes a tacky connector. An example of a cell is 1801 . Each of the cells includes a current collector of an electrode type. A first group of cells 1802 excludes tabs, and a second group of cells 1803 includes tables such as tab 1804. Tacky connector 1805 is partially disposed on the edge.

[0166] In some embodiments, a current collector of an electrode comprises (a) an internal portion on which electrode active material is disposed, and (b) an extension excluding the electrode active material. The extension may be referred herein as “tab.” The current collector assumes a shape of a strip, sheet, or a film.

[0167] In some embodiments, the current collector has an internal portion and a tab. The active material may be disposed on one or both opposing lateral sides of the current collector. In some embodiments, the active material is disposed on (e.g., located on and / or deposited on) the internal portion of the current collector. In some embodiments, the tab is (e.g., substantially) devoid of the active material disposed on the current collector. In some embodiments, the tabs contract along their length, e.g., and along the longest axis of the current collector, e.g., Fig. 10, 1011. The contraction of the tabs along the longest axis may be symmetrical about the longest axis. The symmetry may be about the longest axis. The symmetry may comprise mirror symmetry, or rotational C2 symmetry. Contraction of the tab may be away from the connection line, or from the connection area, of the tab from the internal portion. The contraction may form along a linear or along a nonlinear circumference of a lateral (e.g., horizontal) cross section of the tab. The circumference may include a curved portion and / or a non-curved portion. The tab may be truncated at its end located away from the internal portion of the current collector.

[0168] Fig. 19 shows tab examples. Example 1900 schematically shows a section of the current collector having length similar to the one depicted in Fig. 10, 1002. The tab has a non-contracted section 1906 and a contracted (e.g., narrower such as tapered) section 1905, the contraction being with respect to the maximal width of the current collector. A lateral cross section of the current collector section has a circumference having a truncated top 1903, a non-curved vertical section 1904 (straight line) connected to a curved portion 1902 having a radius, connected to a non-curved horizontal section 1908. The lateral circumference of the (e.g., contracted) tab portion is symmetrical along the long axis 1907 of the current collector. The respective circumference of example 1900 is shown in respective example 1940. In examples 1900 and 1940, the truncated top section (e.g., 1903) as a width that is about twice as long as the length 1906 of the non-truncated section of the tab.

[0169] Fig. 19 shows tab examples. Example 1920 schematically shows a section of the current collector having length similar to the one depicted in Fig. 10, 1002. The tab has a non-contracted section 1926 and a contracted (e.g., narrower such as tapered) section 1925, the contraction being with respect to the maximal width of the current collector. A lateral cross section of the current collector section has a circumference having a truncated top 1923, a non-curved vertical section 1924 (straight line) connected to a curved portion 1922 having a radius, connected to a non-curved horizontal section 1928. The lateral circumference of the (e.g., contracted) tab portion is symmetrical along the long axis 1927 of the current collector. The respective circumference of example 1920 is shown in respective example 1960. In examples 1920 and 1960, the truncated top section (e.g., 1923) as a width that is about 1.5 times as long as the length 1926 of the non-truncated section of the tab. The radius of curvature of the curved section 1902 and 1922 are the same, and the width of the truncated section 1903 is greater than that of 1923. The length of the tabs in 1900 and 1920 is the same, the length of the tab being the length of sections 1905 and 1906, and the length of sections 1925 and 1926, respectively. Example 1980 shows a microscope image of tabs of current collectors of an anode type, as part of a set of cells. Describing the circumference of an example tab, a truncated portion 1981 of the tab, connects to a vertical non-curved portion 1982, that connects to a curved portion 1983, that connects to a horizontal non-curved portion 1984, the tabs surrounded by casing 1985. Example 1980 shows an image of schematics 1920 and 1960.

[0170] In some embodiments, a current collector comprises a planar potion and a tab. The tab may be connected to the internal portion of the current collector by a perforated portion or a non-perforated portion. The perforated portion may comprise one or more holes. The tab may comprise a bent portion and a non-bent portion, e.g., when forming the busbar. The bent portion of the tab may be connected to its internal portion by a perforated portion or a non-perforated portion. The perforation(s) may have a collective width that is at most about 70%, 50%, 40%, or 20% of the maximum width of the tab and / or of the truncated exposed end of the tab. The truncated portion of the tab may have width that is at most about 70%, 60%, 50%, 40%, 30%, or 20% of the maximum width of the tab and / or of the truncated exposed end of the tab. A lateral circumference of the tab may or may not comprise a curvature. A lateral circumference of the tab may or may not comprise a non-curve section. A lateral circumference of the contracted portion of the tab may or may not comprise a curvature. A lateral circumference of the contracted portion of the tab may or may not comprise a non-curve section.

[0171] Fig. 20 shows three-dimensional model examples of various tables. In example 2000, the tab has a truncated exposed end 2001 of a bent portion 2005 of the tab relative to a planar portion 2006 of the tab, bending at about 90 degrees in area such as 2002. The tabhas hole 2003 disposed between two distal connecting sections. Hole 2003 encompasses an imaginary section of bent portion 2005 and an imaginary section of planar portion 2006. The planar section includes non-perforated section having vertical side 2007, planar section 2006 ending with edge 2008 of the tab connects to the internal portion of the current collector (not shown) contacting the electrode active material.

[0172] In example 2030, the tab has a truncated exposed end 2031 of a bent portion 2035 of the tab relative to a planar portion 2036 of the tab, bending at about 90 degrees in area 2032. Bent portion 2065 buckles 2062 before it assumes a planar extent that reaches truncated edge 2061. The tab has planar section 2036 having vertical side 2037, planar section 2036 ending at edge 2038 of the tab that connects to the internal portion of the current collector (not shown) contacting the electrode active material. The tab and the planar section of the current collector can be of a single material section, e.g., single sheet of material, or single foil of material. The tab in example 2030 has a vertical side 2033 perpendicular to truncated portion 2031 . Planar portion 2036 has a circumference comprising a vertical non-curved edge 2037 and a horizontal non-curved edge 2039.

[0173] In example 2060, the tab has a truncated exposed end 2061 of a bent portion 2065 of the tab relative to a planar portion 2066 of the tab, bending at about 90 degrees in area 2062. The tab has planar section 2066 having vertical side 2067, planar section 2066 ending at edge 2068 of the tab that connects to the internal portion of the current collector (not shown) contacting the electrode active material. The tab and the planar section of the current collector can be of a single material section, e.g., single sheet of material, or single foil of material. The tab in example 2060 has a vertical side 2063 perpendicular to truncated portion 2061. Planar portion 2066 has a circumference comprising a vertical non-curved edge 2067 and a horizontal non-curved edge 2069.

[0174] Fig. 21 shows an example of cross sections of various batteries with respect to a Cartesian coordinate system. Example 2100 shows battery cells such as cell 2102 stacked in a direction normal to the z axis, the battery having housing 2101 . 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 2103. 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 of 2103. 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 of stack 2104. The heat may be dissipated from the battery along arrows 2103, e.g., thus increasing the safety of the battery such as by curtailing a runaway reaction.

[0175] Example 2150 shows battery cell 2152 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 2152 isdisposed (e.g. located) in battery housing 2151. 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 2153. 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 of 2153. 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 of stack 2154. The heat may be dissipated from the battery along arrows 2153, e.g., thus increasing the safety of the battery such as by curtailing a runaway reaction. The stacked cell arrangement shown in example 2100 may have a better thermal conductivity as compared to the rolled battery configuration shown in 2150.

[0176] 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, 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 the energy storage 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 noncomposite 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.

[0177] 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 a 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 thebusbar 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 changes occurring 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.

[0178] In some embodiments, a vertical cross section of the (e.g. solid) busbar comprises three rectangles. The horizontal cross section of the (e.g., solid) busbar may span a distance of at least from one distal current collector of one type (e.g., anode current collector) to its opposing distal current collector of that type. The horizontal cross section of the (e.g., solid) busbar may span a distance of at most from one distal end of a casing to its opposing distal end. The horizontal cross section of the (e.g., solid) busbar may span a distance of at most from one end plate to its opposing end plate. The busbar may comprise two portions of the same type (e.g., having the same vertical cross sections - a first portions and a second portion. The first and second portions may have a rectangular vertical cross section. The vertical cross section may be any of the ones disclosed herein. Vertical cross sections of the first portion and of the second portion, can have an aspect ratio of at least about 2:1 , 5:1 , 8.5:1 , 10:1 , 12.5:1 , or 15:1 , the aspect ratio being of a length to a height of the vertical cross section. The busbar may comprise a third portion (e.g., a rectangle) having a vertical crosssection, which can have an aspect ratio of at least about 10:1 , 50:1, 90:1, or 120:1, the aspect ratio being of a length to a height of the third portion. The first portion and the second portion may be separated from each other laterally by a gap. The gap may form a depression relative to an imaginary line connecting the two top exposed surface of the first and the second portion. The third portion may contact a face of each of the first and the second portions, the face opposing the imaginary line. The first and the second portions may be symmetrically aligned about an axis vertically intersecting the length of the busbar's vertical cross section, which may be located (e.g., substantially) at the middle of that length. Each distal side of the first and the second portions, may be aligned with opposing sides of the third rectangular portion, respectively.

[0179] The busbar may have a depression having a vertical cross section, which has an aspect ratio of at least about 7: 1 , 10: 1 , 15:1, 17: 1 , or 20: 1 , the aspect ratio being of its length to its height. A rectangle in which the vertical cross section of the busbar is disposed in, can have an aspect ratio of at least about 10:1, 12:1 , 15:1 , 20:1, 25:1 , 28:1, 30:1 , or 50:1, the aspect ratio being its length to its height. The ratio of the height of the first and / or second portions, to the height of the third portion, can be at least about 1 :1, 2:1, or 3:1. Any two of the rectangular portions may comprise the same class and / or type of material. Any two of the rectangular portions may comprise the a different class and / or type of material. The busbar may be constructed from one block of material, or from different blocks of material, e.g., using mechanical machining. The busbar may be printed from one material type, or from different material types, e.g., using 3D printing.

[0180] Fig. 18 shows in example 1850 a vertical cross section in a (e.g., solid) busbar comprising a first rectangular portion 1851a and a second rectangular portion 1851b separated from each other laterally by a gap having a lateral distance 1855. The gap forming a depression 1852 relative to an imaginary line 1859 connecting the two top exposed surface of rectangular portions 1851a-b. The vertical cross section of the busbar comprises a third rectangular portion 1853 contacting a face of each of rectangular portions 1851a-b, the face opposing imaginary line 1589. Rectangular portions 1851a-b are symmetrically located about axis 1860 vertically intersecting length 1858, (e.g., substantially) at its middle. Each distal side of rectangular portions 1581a-b is aligned with the opposing sides of the third rectangular portion. Each of rectangular portions 1581a-b has height 1851 and a length equal to 1856. The third rectangular portion has a height 1857 and length 1858 defining the length of the busbar. The height of the busbar 1861 includes height 1854 and height 1857. The first rectangular portion and the second rectangular portion, can have an aspect ratio of about 12.5:1, the aspect ratio being of length 1856 to height 1854. The third rectangular portion can have an aspect ratio of about 90:1 , the aspect ratio being of length 1858 to height 1857. A vertical cross section of depression 1852 may have an aspect ratio of about17:1 , the aspect ratio being of length 1855 to height 1854. A rectangle in which the vertical cross section of the busbar is disposed in, can have an aspect ratio of about 28:1 , the aspect ratio being length 1858 to height 1861. The ratio of the height of the first and / or second portions, to the height of the third portion, can be about 2:1 .

[0181] In some embodiments, charge carrier plating can be formed, e.g., during buffering and / or fast charging. Without wishing to be bound by theory, the alloying potential of silicon is higher than the low lithiation voltage of an allotrope of elemental carbon such as graphite, may (a) provide additional margin during fast charging (e.g., or buffering), (b) allow for more excess of anode active material, and / or (c) reduce (e.g., prevent) charge carrier initiated plating such as at high states of charge. At least in part due to silicon’s large volume expansion, the evolution of soft electrical shorts to hard electrical shorts, may be curtailed (e.g., prevented).

[0182] In some embodiments, the contraction and expansion of the cell may cause irreversible damage to the cell, e.g., mechanical and / or chemical change. Adhesion of the welding to the tabs may cause breakage of the tabs during the contraction and expansion. The change may be cause at least in part due to material fatigue, e.g., as the cycling progresses. It may be beneficial to choose materials capable of withstanding the (e.g., accumulating) cycles of expansion and contraction over the (e.g., prescribed) life of the energy storage device. Any anode particles (e.g., comprising silicon) contacting the cathode may discharge and / or shrink such as until the contact is broken.

[0183] Fig. 22 schematically shows a cause for the expansion and contraction of a cel) during charge and discharge states. Example 2200 shows an anode discharge states. Anode active material such as 2201 is separated from cathode active material such as 2202 by a gap in which separator 2203 is disposed. The separator has a perforation (e.g., conduit such as a pinhole) through which charge carriers can transverse from one electrode to its counter electrode. Example 2230 shows an anode charged state. Anode active material such as 2231 is separated from cathode active material such as 2232 by a gap in which separator 2233 is disposed. As compared to the anode discharged state shown in example 2200, the anode active material is inflated, e.g., expanded. The cathode active material is depicted as occupying (e.g., substantially) the same volume between the charged and discharged state.

[0184] Example 2260 shows an anode in which charge carriers are provided. The charge carriers such as 2262 (e.g., lithium cation) become surrounded by a mobile electrolyte such as a fluid or semi-fluid electrolyte, e.g., solvent or gel. The charge carriers propagate through solid electrolyte interphase (SEI) 2235. Deposition 2263 of the charge carriers occurs at least one edge type of the set of cells (e.g., anode) - at its interface; followed by diffusion of the charge carriers into the electrode active material portion 2264, e.g., comprising anallotrope of elemental carbon such as graphite. The deposition may comprise accumulation of the charge carriers at the interface.

[0185] An anode may comprise a material intercalating the charge carriers. The 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 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.

[0186] In some embodiments, the battery is capable of charging. The charging may be at most about 3C, 2C, 1C, 0.5C, 0.25C, 0.2C, 0.15C, or 0.1C. The charging may be between any of the aforementioned values, e.g., from about 3C to about 0.5C, or from about 1C to about 0.1 C. The battery may be configured for (e.g., high energy and / or consumer) electronic applications comprising mobile devices, electrical vehicles, or a guided device. The vehicles may comprise a car, a truck, a plane, or a drone. The mobile device may comprise controllable devices. The mobile device may comprise a wearable, cellular phone, remote controller, console, laptop, tablet, pen, military device, or a medical device. The medical device may comprise an electric shocker. The electric shocker may comprise a defibrillator, electroconvulsive therapy device, or electrical stimulation device. The guided device may comprise a robot, or a propelled vehicle such as a drone. The guided device may be guided in the atmosphere, in the water, and / or on the ground. The guided device may be guided to cross of one or more layers of earth’s atmosphere. The guided device may be guided to propel in one or more layers of earth’s atmosphere. The battery may include the charging capability (e.g., of 3C) for at least about 5min., or 10min. The battery may include the charging capability may be at least about 25%, or 35% state of charge (SOC). As compared to a graphite anode containing battery, a silicon anode containing battery may maintain at least about twice the open circuit voltage (OCV) headroom - the voltage margin between the battery’s OCV at a given SOC, and its maximum allowable voltage. In some examples, the battery is disposed in 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.

[0187] In some embodiments, a velocity of cell charge may be influenced at least in part by a choice of anode material. Fig. 23 shous half-cell curves at 0.05C. Fig. 23 shows an example graph of State of Charge (SOC) as a function of potential in a half cell having an anode comprising graphite 2302, and a half cell having an anode comprising silicon - carbon composite (Si-C) - 2301. The graph shows that there is a 35% SOC cutoff limit 2303 for fast charge operation (e.g., step) in the case of the Si-C anode cell. Initial buffering of the electrode (e.g., anode) with charge carriers 2304 is shown at the beginning of charge (BOC), can reduce resistance and overpotential when initially starting fast charge. Fig. 23 shows an example in which the charge carriers are lithium, and the electrode is an anode. As shown in 2305, at TOC, the anode is about 90% full. When the cell has about 10% of N-P, it may avoid charge carrier plating near top of charge (TOC) state, as shown in 2304. The N / P ratio refers to the ratio of the negative electrode capacity (N) to the positive electrode capacity (P). A N / P greater than 1 may signify excess of anode capacity to hinder (e.g., prevent) lithium plating during charging, e.g., improving safety and cycle life. The N / P ratio 2305 is about 1.1. The N / P ratio 2507 is about 1 .0. In this example, the N / P ratio is about 1 .1 N-P at 2305, using an anode having 50 millivolts of headroom during the Constant Voltage (CV) operation upon charge. The energy penalty in case of a 10% excess Si-C anode is a small and can provide excess anode space to hinder (e.g., avoid) lithium plating.

[0188] 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 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 beginning of charge (BOC), e.g., without buffering (e.g., without pre- lithiation), as is shown in 2306.

[0189] In some embodiments, the anode comprising silicon is thinner than an anode comprising graphite, e.g., has a smaller height - Fig. 10, 1005. 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 ofthe 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 such as lithium plating.

[0190] Fig. 24 shows an example 2400 of a cell. The cell includes an anode having an anode current collector 2401 comprising copper, and graphite anode active material 2402. The anode and the cathode are separated by a gap comprising separator 2403. The cell includes a cathode having a cathode current collector 2404 comprising aluminum, and cathode active material comprising lithium cobalt oxide (LCO) 2405. Fig. 24 shows an example 2450 of another cell. The other cell includes an anode having an anode current collector 2451 comprising copper, and anode active material 2452 comprising silicon as SiOx. The anode and the cathode are separated by a gap comprising separator 2453. The cell includes a cathode having a cathode current collector 2454 comprising aluminum, and cathode active material 2455 comprising lithium cobalt oxide (LCO). Fig. 24 shows an example where LCO-graphite cell has a thicker graphite anode as compared to the thinner silicon-based anode in an LCO-SiOx electrode, the In Fig. 24, the silicon-based anode is about 65% of the thickness of the graphite based anode. The example shown in 2400 is taken from Dixon-Warren, Sinjin, The World of Lithium-Ion Batteries, EE Power, Technical Articles (May 13, 2020).

[0191] In some embodiments, the cell undergoes pre-loading with charge carriers, e.g., before regular use. The pre-loading may comprise “pre-lithiation.” The pre-loading (e.g., 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.

[0192] Fig. 25 shows an example of charge carrier (e.g., Lithium) source 2501 located immediately adjacent to an edge of a set of cells in battery 2502. Due to the cell’s arrangement having their stacking direction along the Y axis, and their edges pointing towards opposing sides along the X direction, it may be impractical to diffuse the charge carriers along the stacking axis, e.g., due to longer and / or inhomogeneous diffusion. In thiscell set configuration, it may be more beneficial to allow the charge carriers to diffuse from one or both opposing side along the X axis. The example in fig. 25 is depicted with respect to a Cartesian coordinate system. The stacked cells may span tenths of millimeters in the stacking direction, e.g., at least about 10, 50, or 100 millimeters. The cells may span a length along the X axis of at least about 1, 2, 3, 5, 6, or 8 millimeters. The cells may span a length along the X axis of at most about 2, 3, 5, 6, 8, or 10 millimeters.

[0193] In some embodiments, the battery undergoes plating associated with the charge carriers, e.g., lithium plating. The plating may at least in part cause a poor cycle life of the battery. Such plating can generate cell gassing, e.g., through reaction with a chemical component of the battery such as an electrolyte. Such plating can generate heat, e.g., from a short. The short may compromise the safety of the battery, e.g., by initiating a runaway reaction.

[0194] The set of cells may undergo a (e.g., fast) charge cycle life. Figs. 26 and 27 show example graphs showing various performance attributes of Lithium-ion batteries having a Si- C anode and an LCO cathode arranged in a set of cells similar to the one depicted in Fig.14. Example 2600 of Fig. 26 shows fast charge (2.8C) life cycle at 25°C, showing capacity retention as a function of cycle number. 2601 depicts a graph of 0.2C discharge, and 2602 depicts a graph of 0.7C discharge. The graph in example 2600 shows that it took about 1000 cycles to reach 20% fade at 0.2C, and to reach 25% fade at 0.7C. Fig. 26 shows a graph of Z growth (e.g., expansion) as a function of number of cycles. Fig. 26 shows that the maximum thickness change during cycling was less than 8%, and less than 7.5%.

[0195] In some embodiments, the cell may undergo pre-charging, or initial charging, by the charge carriers, e.g., into the anode. The pre-charging may be also referred to herein as “buffering.” The buffering may cause lithium plating, which may cause deterioration of the casing and / or of deterring deformation (e.g., expansion and / or buckling) of the battery. Reduction of such plating may be requested and / or desirable. The battery may demonstrate a step-change Increase in battery capacity, increased with cycle life, enhanced thermal performance (e.g., in lower, higher, or lower and higher temperatures), and / or superior charge rate requirements, as compared to other batteries currently available in the market. The battery may utilize (e.g., may be agnostic to) various cathode active material, various electrolytes, and / or various separator materials. The anode active material may comprise high-capacity silicon, the capacity being of binding and / or intercalating the charge carriers. The higher temperature may be of at most about 60°C, 70°C, 80°C, or 90°C. The higher temperature may be of at least about 40°C, 50°C, 60°C, 70°C, or 80°C. The lower temperature may be of at most about -10°C, -20°C, -30°C, or a lower temperature. The lower temperature may be of at least about -20°C, -10°C, 0°C, or a higher temperature. The temperature may be between any of the above referenced values.

[0196] Figs. 27-30 show example images showing Lithium-ion batteries having a Si-C anode and a LCO cathode arranged in a set of cells similar to the one depicted in Fig. 14, undergoing buffering with charge carriers - lithium pre-charging. The cells were cycled at least 400 times.

[0197] Example 2700 shows lithium plating evident in area 2701 of casing 2702 the casing having a constraint that includes oblong holes such as 2703. Example 2730 shows separators of the cell depicted in example 2700, the separator such as 2731 showing significant lithium deposition in area 2732. Dark areas of the separator such as dark area 2733, designate anode active material contacting the separator.

[0198] Example 2800 shows a battery cell after 442 cycles of charge and discharge, the battery cell showing lithium plating evident in a much smaller area 2801 of casing 2802, the casing comprising a constraint that includes oblong holes such as 2803. Example 2850 shows separators of the cell depicted in example 2800, the separators such as 2851 and 2852. While separator 2851 shows minimal lithium plating. Dark areas of the separator such as dark area 2852, designate anode active material contacting the separator.

[0199] Example 2900 shows the battery cell of example 2700, including lithium plating evident in area 2901 of casing 2902 the casing comprising a constraint that includes oblong holes such as 2903. Dark areas of the separator such as dark area 2931 , designate anode active material contacting the separator. Example 2930 shows area 2932. Example 2960 shows a magnified image of area 2932, depicting lithium plating in 2961.

[0200] Example 3000 shows the battery cell of example 2800, having casing 3002 the casing comprising a constraint that includes oblong holes such as 3003. Dark areas of the separator such as dark area 2331 , designate anode active material contacting the separator. Example 3030 shows area 3032. Example 3060 shows a magnified image of area 3032, depicting minimal, or no, lithium plating.

[0201] In some embodiments, the electrode comprises a current collector extending beyond the section contacting the electrode active material. The electrode current collector may extend beyond the largest surface area of the electrode to one side, and the counterelectrode current collector may extend beyond the largest surface area of the counter electrode to an opposing side to the one side. At least one of (a) the electrode current collector and (b) the counter-electrode current collector, comprises the D-slot. In some embodiments, a respective internal skeleton busbar may be inserted into the D-slot of the electrodes, e.g., by connecting their respective current collectors to the busbar. The connection of the current connectors with the busbar may comprise forming an electrical contact between the current connectors and the busbar. Formation of the electrical contact may comprise welding, sintering, or adding a tacky connector such as disclosed herein. In some embodiments, there is a difference in a volume of the cell between a state of chargeand a state of discharge of an electrode of the cell. The connection of the current connectors with the busbar may be configured to allow the cell volume to reversibly change between the state of charge and the state of discharge repeatedly, e.g., using the tacky connector.

[0202] 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.

[0203] 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 maycomprise 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, or proportional-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.

[0204] Fig. 31 shows a schematic example of process 3120 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 3105 to comparator 3106 that generates an error signal, which is fed 3145 into controller 3140. In other control systems, the comparator can be part of the controller. Controller 3140 generates a control signal that is fed into controlling element 3130. The controlling element may comprise a mechanism utilized for its control function to control process 3120. Controlling element 3130 provides an input to process 3120. The mechanism may effectuate a physical and / or a chemical change, which change is the input to process 3120. 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 3120 can be any process disclosed herein, e.g., any method such as a fabrication (e.g., manufacturing) method. Process 3120 generates an output detected by measuring element 3110, e.g., using its sensor(s). The output provided by process 3120 may be a reaction of the process to the input provided by control element 3130. Measuring element 3110 generates a variable amplitude signal that is fed back into comparator 3106 and is again compared with the setpoint. Measuring element 3110 optionally also generates a controlled variable 3181. Control element 3130 optionally also receives a manipulated variable 3182, e.g., from an external source such as a processor and / or a communication system. Sensor(s) can be used by measuring element 3110 for the measurement of parameters of the process, e.g., 3120. The sensor measurement can be adetermination 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 3105), 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., 3140), or within the controller. The reference point (e.g., set point) can be stored in the memory of the controller, or of a memory operatively 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., 3140) 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., 3130. 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., 3130) can be a device that controls an incoming material to the process, or any other attribute of the process comprising physical attribute or 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., 3110) 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 orbe 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.

[0205] Control may comprise regulate, modulate, adjust, maintain, alter, change, govern, manage, restrain, restrict, direct, guide, oversee, manage, preserve, sustain, restrain, temper, or vary.

[0206] 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. 32 shows a schematic example of a computer system 3200 that is programmed or otherwise configured to facilitate execution any of the methods provided herein.The computer system 3200 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 3200 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 3200 can include a processing unit 3206 (also “processor,” “computer” and “computer processor" used herein). The computer system may include memory or memory location 3202 (e.g., randomaccess memory, read-only memory, flash memory), electronic storage unit 3204 (e.g., hard disk), communication interface 3203 (e.g., network adapter) for communicating with one or more other systems, and peripheral devices 3205, such as cache, other memory, data storage and / or electronic display adapters. The memory 3202, data storage unit 3204, interface 3203, and peripheral devices 3205 are in communication with the processing unit 3206 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”) 3201 , e.g., with theaid 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 3202. The instructions can be directed to the processing unit, which can subsequently program or otherwise configure the processing unit 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 processor 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 can be part of a circuit, such as an integrated circuit. One or more other components of the system (e.g., 3200) can be included in the circuit.

[0207] In some embodiments, the storage unit (e.g., 3204) 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.

[0208] In some embodiments, the system, device, and / or apparatus disclosed herein comprises communicating through a network. The computer system can communicate withone 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.

[0209] 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 the computer system, such as, for example, on the memory 3202 or electronic (e.g., data) storage unit 3204. The machine executable or machine-readable code can be provided in the form of software. During use, the processor (e.g., 3206) 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.

[0210] 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 orinstructions, 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.

[0211] 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 comprise Bluetooth, 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.

[0212] In some embodiments, the cells are manufactured, e.g., to form a battery. The tacky connector may be applied at a glass or at a melting temperature of at least one component of the tacky connector, e.g., at a temperature of at least about 100°C, 150°C, 200°C, or 250°C. The application of the tacky connector 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 hardened tacky connector may have a thickness of at least about 50 pm, 100 pm, or 150 microns (pm). 100 microns thickness, then we are down to about 50 microns after applying it. The tacky connector may have a resistance. The resistance may be at most about 0.1 , 0.2, 0.5, 1, or 2 ohms (Q).

[0213] In some embodiments, a battery is manufactured. The battery can be fabricated (e.g., fabricated). The environment may or may not be an ambient environment. The environment may comprise one or more environmental characteristics different than those of the ambient environment. The one or more characteristics may comprise a lowerconcentration of reactive agent, a higher temperature, or a higher pressure. The reactive agent may react with one or more components of the battery, e.g., during its use, storage, shipping, maintenance, and / or fabrication. The battery 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. The direct printing may comprise additive manufacturing. 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.

[0214] Example 1

[0215] In a clean dry air environment, battery cells were fabricated in a configuration similar to the one depicted in Fig. 13, the cells comprising an anode having a copper current collector and Si-C active material, a cathode having LCO and an aluminum current collector, the cathode and anode being separated by a gap comprising a separator that facilitates lithium charge carrier to travel therethrough. Each of the charge collectors have a tab. The cells were stacked along a stacking axis, the tabs of the anode emerged on one side of the stacked cells, and the tabs of the cathode current collectors emerged on the opposing side of the stacked cells. The cathode tabs were pulled, folded, and welded. The anode tabs were similarly pulled, folded, and welded. Solid busbars were added to each of the welded cathode tabs side and of the welded anode tabs side. Any remaining non-filled space was filled with a polymer at 200°C and at a pressure of 20 psi.

[0216] Example 2

[0217] In a clean dry air environment, battery cells were fabricated in a configuration similar to the one depicted in Fig. 13, the cells comprising an anode having a copper current collector and Si-C active material, a cathode having LCO and an aluminum current collector, the cathode and anode being separated by a gap comprising a separator that facilitates lithium charge carrier to travel therethrough. Each of the charge collectors have a tab. The cells were stacked along a stacking axis, the tabs of the anode emerged on one side of the stacked cells, and the tabs of the cathode current collectors emerged on the opposing side of the stacked cells. The cathode tabs were pulled, folded, and welded. The anode tabs were similarly pulled, folded, and welded. A tacky connector (e.g., adhesive) was added to each of the welded cathode tabs side and of the welded anode tabs side. Any remaining non-filled space was filled with a non-conductive material (a polymer) at 200°C and at a pressure of 20 psi.

[0218] The processes discussed above are intended to be illustrative and not limiting. One skilled in the art would appreciate that the actions described with respect to the processes discussed herein may be omitted, modified, combined, and / or rearranged, and any additional actions may be performed without departing from the scope of the invention. More generally, the above disclosure is meant to be examples and not limiting. Only the claims that follow are meant to set bounds as to what the present invention includes. Furthermore, it should be noted that the features and limitations described in any one implementation may be applied to any other implementation herein, and flowcharts or examples relating to one implementation may be combined with any other implementation in a suitable manner, done in different orders, or done in parallel. In addition, the systems and methods described 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.

[0219] 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 energy manipulation, the device comprising: a first battery cell comprising a first electrode separated from a first counter electrode by a first gap, the first electrode including a first electrode current collector comprising a first electrode internal portion that extends into, and / or contacts, a first electrode external portion that is a first electrode tab, the first electrode internal portion contacting a first electrode active material, the first electrode tab being devoid of the first electrode active material; and an optional second battery cell comprising a second electrode separated from a second counter electrode by a second gap, the second electrode including a second electrode current collector comprising a second electrode internal portion that extends into, and / or contacts, a second electrode external portion that is a second electrode tab, the second electrode internal portion contacting a second electrode active material, the second electrode tab being devoid of the second electrode active material, wherein:(a) the first electrode current collector having a first axis extending from an exposed end of the first electrode internal portion to an exposed end of the first electrode tab opposing the exposed end of the first electrode internal portion, the first electrode tab comprising a first shape that diminishes along the first axis;(b) the first electrode tab comprising a first portion that buckles along the first axis;(c) the first electrode tab and the second electrode tab contacting a busbar configured for electrical current flow therethrough, the busbar comprising one or more perforations extending from an exposed face of the busbar to an internal face of the busbar, the internal face contacting the first electrode tab and the second electrode tab;(d) the busbar configured to accommodate the first electrode tab and the second electrode tab to facilitate the electrical current flow therethrough and through the busbar, the busbar comprising an indentation configured to accommodate at least the first electrode tab and the second electrode tab;(e) the first electrode tab being configured to bend relative to the first electrode internal portion in a forward direction, and the second electrode tab being configured to bend relative to the second electrode internal portion in a backwards direction opposing the forward direction; or(f) any combination of (a), (b), (c), (d) and (e).

2. The device of claim 1 , wherein the first shape diminishes in shape, cross section, volume, or any combination thereof.

3. The device of claim 1 , wherein the first axis is a median axis of the first electrode current collector.

4. The device of claim 1 , wherein the first shape diminishes along the first axis linearly, or exponentially.

5. The device of claim 1 , wherein the first shape diminishes symmetrically about the first axis.

6. The device of claim 1 , wherein the first electrode current collector has a width normal the first axis, the width being of a face of the current collector contacting the first electrode active material; and optionally wherein (I) the width of the first shape diminishes along the first axis, (II) the width the exposed end of the first electrode tab is the width of the first electrode internal portion, (III) the width the exposed end of the first electrode tab is different from the width of the first electrode internal portion, (IV) the width the exposed end of the first electrode tab is smaller than the width of the first electrode internal portion, (V) the width of the first shape diminishes symmetrically along the first axis; and optionally wherein the width of the first shape diminishes linearly, or exponentially, or (VI) any combination thereof as applicable.

7. The device of claim 1 , wherein the first electrode current collector has a face contacting the first electrode active material; and optionally wherein (I) a circumference of the face of the first shape comprises a curvature, (II) the circumference of the face of the first shape comprises a straight line, (III) circumference of the face of the first shape comprises a curvature and a straight line, or (IV) any combination thereof as applicable.

8. The device of claim 1 , wherein the exposed end of the first electrode tab is truncated.

9. The device of claim 1 , wherein the first electrode tab comprises a second shape that does not diminish; and optionally wherein (I) the second shape does not diminish in shape, cross section, volume, or any combination thereof, or (II) the second shape retains in shape, cross section, volume, or any combination thereof.

10. The device of claim 9, wherein the first electrode current collector has a width normal the first axis, the width being of a face of the current collector contacting the first electrode active material; optionally wherein (I) the width of the second shape is different from the width of the first electrode internal portion, (11) the width of the second shape is smaller than the width of the first electrode internal portion, (III) the width of the second shape is the width of the first electrode internal portion, (IV) the first electrode tab comprises a third shape, or (V) any combination thereof;11 . The device of claim 1 , wherein the first portion buckles in an alternating fashion.

12. The device of claim 1, wherein the first portion buckles in a manner similar to a zigzag, sinus, or top-hat.

13. The device of claim 1 , wherein the first portion buckles in a manner similar to an English letter S, English letter Z, the combination of letters “LI-,” or a Greek letter fl.

14. The device of claim 1 , wherein the first portion buckles along the first axis.

15. The device of claim 1 , wherein the first portion buckles along the first axis in (a) a diminishing amplitude, (b) diminishing pitch, or (c) any combination of (a) and (b).

16. The device of claim 1 , wherein the first portion diminishingly buckles along the first axis.

17. The device of claim 1 , wherein the first portion that diminishingly buckles, contacts the first electrode internal portion.

18. The device of claim 1 , wherein the first portion that diminishingly buckles excludes the first exposed end of the first electrode tab.

19. The device of claim 1 , wherein the first portion that diminishingly buckles has the first exposed end of the first electrode tab.

20. The device of claim 1 , wherein the perforations are configured to release tension, pressure, and / or gas during an operation of the device; and optionally wherein operation of the device comprises electrically charging and / or electrically discharging the device.21 . The device of claim 1 , wherein the one or more perforations comprises a set of perforations; optionally wherein the busbar comprises a length axis, the first electrode tab; and optionally wherein the second electrode tab being disposed along the length axis; and optionally wherein (I) the set of perforations are arranged normal to the length axis, (II) the set of perforations are arranged normal to the length axis symmetrically, (III) the busbar comprises a plurality of perforation sets comprising the set of perforations, and wherein each set of the plurality of perforation sets is arranged along the length axis of the busbar, or (IV) any combination thereof.

22. The device of claim 1 , wherein the indentation is symmetrically disposed along a length axis of the busbar, and wherein upon assembly of the device, the first electrode tab and the second electrode tab are disposed along the length axis of the busbar.

23. The device of claim 1 , wherein the busbar comprises at least two material classes; and optionally wherein the material classes (I) include an elemental metal, a metal alloy, an allotrope of elemental carbon, any plurality thereof, or any combination thereof and / or (I) include a composite material, a non-composite material, any plurality thereof, or any combination thereof.

24. The device of claim 1, wherein the first electrode tab is configured to bend at a smallest first angle of at most about 140 degrees relative to the first electrode internal portion, and wherein the second electrode tab is configured to bend at a smallest second angle of at most about 140 degrees relative to the second electrode internal portion.

25. The device of claim 1 , wherein a first set of electrode tabs include the first electrode tab, and wherein a second set of electrode tabs include the second electrode tab, and whereinthe first set of electrode tabs is configured to bend relative to the first internal portion in the forward direction, and the second set of electrode tabs being configured to bend relative to the second electrode internal portion in the backwards direction; and optionally wherein the busbar comprises at least two material types, the at least two material types belonging to a class of the at least two material classes; and optionally wherein the at least two material types comprise elemental metals, or metal alloys.

26. The device of claim 1 , wherein the device is a battery, or includes the battery; and optionally wherein the battery is a secondary battery.

27. The device of claim 1 , wherein the first counter-electrode including a first counterelectrode current collector comprising a first counter-electrode internal portion that extends into, and / or contacts, a first counter-electrode external portion that is a first counter-electrode tab, the first counter-electrode internal portion contacting a first counter-electrode active material, the first counter-electrode tab being devoid of the first counter-electrode active material; and an optional second battery cell comprising a second counter-electrode separated from a second counter counter-electrode by a second gap, the second counterelectrode including a second counter-electrode current collector comprising a second counter-electrode internal portion that extends into, and / or contacts, a second counterelectrode external portion that is a second counter-electrode tab, the second counterelectrode internal portion contacting a second counter-electrode active material, the second counter-electrode tab being devoid of the second counter-electrode active material; optionally wherein (A) the first counter-electrode current collector having a first axis extending from an exposed end of the first counter-electrode internal portion to an exposed end of the first counter-electrode tab opposing the exposed end of the first counter-electrode internal portion, the first counter-electrode tab comprising a first shape that diminishes along the first axis; (B) the first counter-electrode tab comprising a first portion that buckles along the first axis; (C) the busbar is an electrode busbar, the first counter-electrode tab and the second counter-electrode tab contacting a counter-electrode busbar configured for electrical current flow therethrough, the counter-electrode busbar comprising one or more perforations extending from an exposed face of the counter-electrode busbar to an internal face of the counter-electrode busbar, the internal face contacting the first counter-electrode tab and the second counter-electrode tab; (D) the counter-electrode busbar configured to accommodate the first counter-electrode tab and the second counter-electrode tab to facilitate the electrical current flow therethrough and through the counter-electrode busbar, the counter-electrode busbar comprising an indentation configured to accommodate at least the first counterelectrode tab and the second counter-electrode tab; (E) the first counter-electrode tab being configured to bend relative to the first counter- electrode internal portion in the forward direction, and the second counter-electrode tab being configured to bend relative to thesecond counter- electrode internal portion in the backward direction; or (F) any combination of (A), (B), (C), (D) and (E); and optionally wherein a first set of counter-electrode tabs include the first counter-electrode tab, and wherein a second set of counter-electrode tabs include the second counter-electrode tab, and wherein the first set of counter-electrode tabs is configured to bend relative to the first internal portion in the forward direction, and the second set of counter-electrode tabs being configured to bend relative to the second internal portion in the backwards direction.

28. The device of any of claims 1 to 27, wherein (a) the device comprises a casing housing the first battery cell and the second battery cell, (b) the first battery cell and the second battery cell are horizontally stacked, (c) the device configured for quicker heat dissipation as compared to similar devices currently available, (d) the device being configured to minimize plating of charge carriers, (e) the device being configured for pre-loading of the charge carriers, (f) the device being configured for fast charging, the electrode active material comprises silicon, the electrode being an anode, (f) the device being configured for a thinner anode as compared to conventional anodes comprising graphite, or (g) any combination thereof; and optionally wherein the casing being an anisotropic constraint.

29. A method associated with the device in any of claims 1 to 27, the method comprising: (a) providing the device; and (b) manufacturing, testing, buffering, storing, shipping, or using the device for energy manipulation; and optionally wherein the energy manipulation comprises comprising electrically charging and / or discharging the device.

30. An apparatus for energy manipulation in the device in any of claims 1 to 27, the apparatus comprises: at least one controller configured (A) for operatively coupling with the device, and (B) to execute, or direct at least one component of the device to execute, one or more operations associated with the energy manipulation, and optionally wherein the at least one controller is configured to operatively couple to a power source and / or with a communication platform.31 . 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 one or more components of device in any of claims 1 to 27, are configured to execute, or direct execution of, one or more operations associated with the device and / or with the energy manipulation.

32. A method of fabricating the device in any of claims 1 to 27, the method comprising: operatively coupling the first tab and the second tab to facilitate the electrical current flow.

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