Surge protection systems for electrochemical cell assemblies

Abstract

The present inventions relate to methods, systems, apparatuses, controllers, software, and compositions of matter associated with protecting electrochemical cell assemblies against thermal runaway initiated by electrically conductive foreign objects, e.g., by configurations that redirect discharge during nail penetration toward a shield-coupled electrodes electrically connected with terminals of a cell assembly, before the foreign object reaches the cell assembly.

Description

SURGE PROTECTION SYSTEMS FOR ELECTROCHEMICAL CELL ASSEMBLIES

[0001] This application claims priority to U.S. Provisional Patent Application Serial No. 63 / 658,233, filed on June 10, 2024, which is incorporated herein by reference in its entirety for all purposes.BACKGROUND

[0002] The present invention relates to methods and structures such as electrode assemblies for use in energy manipulation (e.g., storage and / or release) devices such as secondary batteries, to energy manipulation devices employing such structures, and to methods for manufacturing such structures and energy manipulation devices.

[0003] Batteries are a type of energy manipulation device having electrochemical cells in which carrier ions travel between a cathode structure and an anode structure through an electrolyte within each electrochemical cell (e.g., voltaic cell) abbreviated herein as “cell.” The anode structure and cathode structure in the cell are separated by a gap. The cell may include a separator structure. The separator structure may be incorporated in the battery cell during assembly of the battery and during battery operation. Anode and cathode current collectors of the respective anode and cathode, pool electric current from the respective active electrochemical electrodes and enable transfer (e.g., flow) of the current to the environment outside the battery.

[0004] In an example, batteries comprise oppositely charged electrodes separated by a gap and immersed with an electrolytic mixture. An electrode may comprise a current collector coupled with an active material type. The electrochemical cell may be encased by an enclosure (e.g., a flexible pouch or a rigid can), e.g., that may be sealed in a liquid tight and / or gas tight manner. The cell assembly may be provided in stacked and / or wrapped configurations. To meet commercial safety requirements, the device (e.g., battery) may be tested, e.g., using foreign object penetration such as metallic nail penetration. The test may follow standardized procedures, e.g., nail penetration test. During such tests, a conductive object (e.g., a nail) may short opposing electrodes of a charged cell. The short may trigger thermal runaway reactions. Mitigation approaches may include safety features located inside the enclosure and / or outside of the enclosure of the device. The safety features may comprise one or more shields. The features may rely at least in part on resistive and / or interrupting elements. The safety mechanisms may reduce energy density and / or impact cycle performance.

[0005] In an example, lithium-based secondary batteries are a type of energy storage device having cells in which carrier ions, such as lithium, sodium, potassium, calcium or magnesium ions, travel between a cathode structure and an anode structure through an electrolyte withineach cell. The anode structure and cathode structure are separated by a separator structure during assembly of the battery and during battery operation. Anode and cathode current collectors pool electric current from the respective active electrochemical electrodes and enable transfer of the current to the environment outside the battery. There are a number of shortcomings related to (e.g., secondary) batteries and the process of making secondary batteries. For example, secondary batteries must pass certain safety tests before being placed in consumer devices. One of these tests is the nail penetration safety test. This test requires that the battery include a mechanism to redirect a shorting current after a nail penetrates the battery during operation. However, these mechanisms often have a negative impact on cell performance.

[0006] In some energy manipulation devices, the structural configuration of the cell enclosure may influence vulnerability to direct electrical shorting. Cell assemblies enclosed by a flexible pouch may be more susceptible to exposing the cell assembly to external impact and / or puncture events, e.g., since they are less resistive to penetration of a sharp object such as a nail. When a foreign object connects the cathode and the anode through direct contact, an energetic arching may occur, followed by a strong current discharge. The foreign object may or may not be conductive. In the event the foreign object is not conductive, the foreign object may be otherwise configured to allow a charged entity (e.g., electrode) to reach an oppositely charged entity (e.g., counter electrode) sufficiently close to form an electrical arch and / or cause electrical coupling between the two opposing electrodes by penetration of the foreign object. The arching and / or discharge, may lead to localized heating. The heating may initiate degradation, gas evolution, and / or runaway reaction, e.g., thermal runaway reaction. Even short-lived arcs and / or sparks generated on initial penetration of the foreign object approaching the electrodes, may lead to a harmful effect - a harm, e.g., an adverse (e.g., catastrophic) event to the device, to personnel sch as a user, to the ambient environment external to the device such as to the facility in which the device is disposed, or any combination thereof.

[0007] In an example, a penetrating object can carry electrical charge when electrically coupled with one terminal, discharging upon reaching the counter electrode and generating an arc. The energy released during this arch event (e.g., spark) may exceed the thermal tolerance of the internal electrolyte system, and trigger exothermic side reaction(s). Thermal management systems and internal barriers may not respond rapidly enough to prevent damage. Shielding elements external to the sealed cell have been considered to attenuate the arc energy before reaching internal electrodes.

[0008] In an example, secondary batteries must pass certain safety tests before being distributed to customers, e.g., before being placed in consumer devices. One of these tests is the nail penetration safety test, e.g., a critical safety test for lithium batteries, simulating aninternal short circuit caused by physical damage. The battery passes this test if it avoids fire, explosion, significant smoke end / or otherwise significant (e.g., harmful) thermal runaway reaction. Such test may be passed when the battery includes a mechanism to dissipate (e.g., by redirecting) the energy carried by the foreign object from the cell assembly. Such mechanisms often have a negative impact on cell performance. There is a requirement for structures that curtail thermal runaway while preserving cell performance.TECHNICAL FIELD OF THE INVENTION

[0009] The present invention relates to safety protection of electrochemical cell assemblies. The protection may be using shields, and / or surrounding structures that conductively interact with a penetrating object. In an example, the shields facilitate flow of the energy conducted from one shield electrode to its opposing shield electrode through the conductive penetrating object (e.g., nail). The invention relates to electrode configurations to curtail thermal runaway events in the cell assembly during penetration incidents of sharp (e.g., electrically conductive) foreign objects, e.g., for use in energy storage devices.SUMMARY

[0010] In some aspects, the present disclosure resolves one or more of the aforementioned hardships and / or shortcomings. In some aspects, the present closure provides solutions to curtail the aforementioned hardships and / or shortcomings. The solutions include method(s), device(s), apparatus(es), system(s), software, and / or design(s). In some aspects, the present inventions relate to method(s), device(s), apparatus(es), system(s), software, and design(s), utilized for a battery comprising cell(s) - forming a cell assembly. Methods, apparatuses, devices, program instructions, and structures are disclosed herein to generate electrical shields for a cell assembly. The shield may comprise sheets of conductive material (e.g., metal). In an example, a conductive material (e.g., in the form of a wrapped sheet) coupled with one of the terminals and disposed in a path of the approaching foreign object towards a counter electrode shield and finally to the cell assembly, may allow discharge to occur externally from the cell assembly and before the foreign object approaches the cell assembly sufficiently to form an arc (e.g., spark) discharge with opposing electrodes of the cell assembly. When located appropriately, the conductive material of the opposingly charged shields, may be sufficient to dissipate energetic surges, redirect harmful electrical current, and / or otherwise limit internal damage to the cell assembly.

[0011] In some aspects, the present disclosure relates to a construct designed to curtail thermal runaway resulting from electrical faults induced by mechanical penetration of a foreign object into the cell assembly. The construct includes an electrochemical cell assembly and a pair of shields capable of carrying opposing electrical charges derived from the cell assembly. The electrochemical cell assembly and the shields may be electrically coupled by oppositely charged terminals of the cell assembly, e.g., an electrode terminal and a counter-electrodeterminal. A conductive foreign object penetrating the construct may trigger an initial surge of electrical energy between oppositely charged shields. The surge may result in an arc or spark prior to contact with the cell assembly. The shields may be positioned to intercept the object and absorb energy externally to the cell assembly. The arc even may or may not occur outside the electrolyte region enclosure in the enclosure. The configuration of the construct may reduce the probability of thermal runaway reaction initiation within the active region of the cell assembly. The invention can support compliance with jurisdictional and other device standards (collectively referred to herein as “Standards”), including safety tests (e.g., nail penetration test), e.g., by providing energy diversion pathways external to the cell assembly. The design may enhance the safety of electrochemical cells during intrusion events.

[0012] In some aspects, the present disclosure relates to a shielding arrangement that diverts the location of an initial energy surge to remain outside the electrochemical cell assembly. Each terminal of the cell assembly is electrically coupled with a shield capable of carrying a matching electrical polarity. The shields are separated by a gap, e.g., comprising an insulating layer - a shield insulator. The polarity assignment and location are configured such that a penetrating conductive object first encounters the shields before reaching the electrodes of the cell assembly. The shield-coupled electrodes (SCE) are arranged to receive and dissipate the majority of the electrical energy surge during the penetration of the foreign objects towards the cell assembly. The surge may occur (e.g., just) prior to a possibility of an internal shorting, e.g., and may take the form of an arc and / or spark. The arc event occurring between the foreign object and at least one of the shield layers and / or between the two shield layer (e.g., when the foreign object is non-conductive). The more distant the arc location is from the internal cell assembly, the lower the thermal impact may be on the cell assembly. Although the foreign object may eventually enter the cell assembly, the advance dissipation of electrical energy may reduce a chance (e.g., substantially and / or measurably prevent) a harmful thermal runaway event within the electrochemical core.

[0013] In some aspects, systems and methods are disclosed herein for wrapping a battery cell with thin metal foil of sufficient length and welding the foil to one of the cell tabs to redirect the shorting current after nail penetration to the metal foil, preventing a hot spot and thermal runaway. The systems and methods disclosed herein can allow for passing of the nail penetration safety tests without any negative impact on cell performance (i.e. , cycle life, rate capability, and high and low temperature performance) - a (e.g., only) drawback being an energy density reduction, e.g., due to the addition of inactive material to the cell thickness.

[0014] In another aspect, a method for manufacturing a secondary battery, the method comprises: producing an electrode assembly comprising a plurality of unit cells stacked in a stacking direction, each of the unit cells comprising an anode structure, a separatorstructure, and a cathode structure; producing the secondary battery comprising a battery enclosure, and the electrode assembly and an electrolyte within the battery enclosure; and wrapping the secondary battery with a plurality of wraps of a metal foil having a metal foil length and at least one wrap of a carbon double-sided tape having a copper foil.

[0015] In another aspect, a secondary battery comprising a battery enclosure, and 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 unit cells comprising an anode structure, a separator structure, and a cathode structure, wherein the secondary battery comprises a plurality of wraps of a metal foil having a metal foil length, and at least one wrap of a carbon double-sided tape having a copper foil.

[0016] In another aspect, a device for conducting electricity, the device comprises: a cell assembly comprising one or more unit cells, the cell assembly comprising an electrode and a counter-electrode, the electrode comprising electrode active material coupled with an electrode current collector, the counter-electrode comprising counter-electrode active material coupled with a counter-electrode current collector the electrode current collector being electrically coupled with an electrode terminal tab and the counter-electrode current collector being electrically coupled with a counter-electrode terminal tab, each of the electrode terminal tab and the counter-electrode terminal tab being configured to couple with an external source for conducting the electricity relative to the cell assembly; a counterelectrode shield electrically coupled with the counter-electrode terminal tab, the counterelectrode shield being electrically conductive, the counter-electrode shield being disposed external to the cell assembly, the counter-electrode shield being physically coupled with the cell assembly; an electrode shield electrically coupled with the electrode terminal tab, the electrode shield being electrically conductive, the electrode shield being disposed external to the cell assembly, the electrode shield being physically coupled with the counter-electrode shield, the electrode shield being separated from the counter-electrode shield by a gap, the electrode shield being disposed further away from the cell assembly relative to the counterelectrode shield; and a shield separator disposed between the electrode shield and the counter-electrode shield, the shield separator being disposed in the gap, the shield separator comprising an electrically insulating material, the electrode shield and the counter-electrode shield being configured such that a foreign object (e.g., which is conductive) that progresses in a path towards the cell assembly, will successively penetrate the electrode shield, the shield separator, and the counter-electrode shield to cause an electrical short that discharges electrical energy outside the cell assembly, before the foreign object reaches the cell assembly. In some embodiments, the cell assembly comprises (i) a stacked architecture comprising a plurality of unit cells arranged along a stacking axis, (ii) a wrapped cell architecture comprising a wound electrode-separator structure, or (iii) any combinationthereof. In some embodiments, the cell assembly generates a prismatic cell having face types of at least two types, or of at least three types, and wherein (a) the stacking axis is normal to the face type having the largest surface area and / or (b) the stacking axis is normal to a face type other than the face type having the largest surface area, the face type being or the face types. In some embodiments, the electrode comprises a cathodically active material comprising cobalt, a metal oxide, any plurality of types thereof, or any combination thereof. In some embodiments, the cathodically active material comprises lithium cobalt oxide. In some embodiments, the counter-electrode comprises an anodically active material comprising silicon or an allotrope of elemental carbon. In some embodiments, the allotrope of elemental carbon comprises graphite, hard carbon, soft carbon, carbon nanotubes, carbon nanowires, carbon particulate matter, graphene, any plurality of types thereof, or any combination thereof. In some embodiments, the carbon particulate matter comprises a size distribution in nanoscale or in microscale. In some embodiments, the allotrope of elemental carbon conducts electricity. In some embodiments, the anodically active material comprises porosity. In some embodiments, the anodically active material comprises a composite material. In some embodiments, the electrode active material comprises cobalt, lithium, iron, phosphate, or an allotrope of elemental carbon. In some embodiments, the allotrope of elemental carbon comprises carbon nanotubes, carbon nanowires, graphene, or carbon particulate matter, any plurality of types thereof, or any combination thereof. In some embodiments, the carbon particulate matter comprises a size distribution in nanoscale or in microscale. In some embodiments, the allotrope of elemental carbon conducts electricity. In some embodiments, the anodically active material comprises a non-composite material. In some embodiments, the electrode current collector and / or the counter-electrode current collector, comprises a metal sheet comprising an elemental metal, a metal alloy, any plurality of types thereof, or any combination thereof. In some embodiments, the metal sheet comprises aluminum, nickel, copper, any plurality of types thereof, or any combination thereof. In some embodiments, the sheet is in the millimeter scale, or the sheet comprises a foil having a thickness in the microscale. In some embodiments, the metal sheet comprises a metal sheet, the foil having a thickness in the microscale. In some embodiments, the counter-electrode current collector is of a different type of material than the electrode current collector. In some embodiments, the foreign object is electrically conductive. In some embodiments, the foreign object is non-electrically conductive. In some embodiments, the electrode current collector is electrically coupled with the electrode terminal tab at least in part by welding, by using a tacky conductive material, any plurality of types thereof, or any combination thereof. In some embodiments, the tacky conductive material comprises an elemental metal, a metal alloy, an allotrope of elemental carbon, any plurality of types thereof, or any combination thereof. In some embodiments, the allotrope of elemental iselectrically conductive. In some embodiments, the tacky material comprises a composite material or a non-composite material, carbon, a carbon-polymer composite, an adhesive sheet, or any combination thereof. In some embodiments, the tacky conductive material is disposed between the electrode current collector and the electrode terminal tab (e.g., at an interface region). In some embodiments, the tacky conductive material couples the electrode current collector with the electrode terminal tab. In some embodiments, the tacky material is applied at least in part by lamination, compression, bonding, or any combination thereof; and wherein the tacky material is configured to maintain electrical conductivity under mechanical deformation. In some embodiments, the tacky material is elastic under the prescribed conditions of the device. In some embodiments, the electrode terminal tab and the counterelectrode terminal tab are each configured to couple with an external system comprising an electrical power source and / or an electrical device. In some embodiments, the external system comprising wiring, a circuit interface, a battery management unit, a test fixture, or any combination thereof. In some embodiments, each of the terminal tabs comprise an elemental metal, a metal alloy, any plurality of types thereof, or any combination thereof. In some embodiments, the terminal tab comprises copper, aluminum, nickel, any plurality of types thereof, or any combination thereof. In some embodiments, the terminal tabs comprise, or are operatively coupled with, a component, the component comprising an insulation sleeve, a thermal buffer layer, a current-limiting fuse element, a grommet, or any combination thereof. In some embodiments, the component is operatively coupled with the external system. In some embodiments, the component is operatively coupled with the external system at least in part by welding, clamping, a compression connector, or any combination thereof. In some embodiments, the cell assembly is disposed in a housing comprising an insulating material. In some embodiments, the housing comprises a layerwise structure comprising a conductive layer disposed between opposing insulating layers. In some embodiments, the conductive layer comprises aluminum. In some embodiments, the insulating layers comprise a polymer, a resin, any plurality of types thereof, or any combination thereof. In some embodiments, the housing is hermetically sealed, gas-tight, and / or liquid-tight. In some embodiments, the housing encloses a liquid electrolyte disposed within a sealed volume of the housing. In some embodiments, the electrolyte comprises alkali and / or alkali earth charge carriers. In some embodiments, the charge carriers comprise lithium. In some embodiments, the device is configured to undergo charge and discharge cycles as part of a secondary battery. In some embodiments, the counterelectrode shield comprises a constraint system electrically coupled with the counterelectrode terminal tab, the constraint system comprising an elemental metal, a metal alloy, an allotrope of elemental carbon, any plurality of types thereof, or any combination thereof. In some embodiments, the constraint system comprises a non-composite material, acomposite material, any plurality of types thereof, or any combination thereof. In some embodiments, the constraint system comprises stainless steel, or any plurality of types thereof. In some embodiments, the stainless steel comprises SS-301 or SS-316. In some embodiments, the allotrope of elemental carbon comprises carbon fibers as non-woven or as a woven structure. In some embodiments, the composite material comprises braided and / or layered conductive elements. In some embodiments, the constraint system is configured to permit diffusion of charge carriers therethrough. In some embodiments, the constraint system comprises a non-particulate sheet or foil. In some embodiments, the constraint system comprises a coating, the coating being an electrically insulating coating. In some embodiments, the coating comprises ClearClad, polyimide, or any combination thereof. In some embodiments, the constraint system is physically coupled with the cell assembly using a tacky material disposed at an interface between the constraint system and the cell assembly. In some embodiments, the tacky material is patterned to allow release of at least a portion of the electrode during volumetric expansion of the cell assembly during a prescribed use of the device. In some embodiments, an insulator is disposed between the cell assembly and the counter-electrode shield comprising the constraint system. In some embodiments, the insulator comprises a ceramic material, or any plurality of types thereof. In some embodiments, the ceramic material comprises alumina, boehmite, any plurality of types thereof, or any combination thereof. In some embodiments, the insulator comprises a discrete layer or a laminate. In some embodiments, the insulator is disposed within a housing in which the cell assembly is located. In some embodiments, the insulator is disposed outside of the housing in which the cell assembly is located. In some embodiments, the insulator is included in the housing in which the cell assembly is located. In some embodiments, the insulator is configured to electrically isolate the counter-electrode shield from the active components of the cell assembly while permitting thermal conduction and / or mechanical support. In some embodiments, the electrode shield comprises a structure devoid of particulate material, a sheet, a foil, a layered structure, a wound structure disposed about an axis while enveloping the cell assembly to form an envelope, the counterelectrode shield, or any combination thereof. In some embodiments, the envelope is a cylindrical envelope. In some embodiments, the envelope is open at its two distal and opposing ends. In some embodiments, the electrode shield comprises, or is operatively coupled with a tacky conductive material disposed over a conductive base layer. In some embodiments, the tacky conductive material comprises an elemental metal, a metal alloy, an allotrope of elemental carbon, any plurality of types thereof, or any combination thereof. In some embodiments, the allotrope of elemental carbon comprises a carbon-polymer matrix, any plurality of types thereof, or any combination thereof. In some embodiments, the tacky conductive material is disposed an otherwise exposed surface of the electrode shield. Insome embodiments, the otherwise exposed surface is located farthest from the cell assembly. In some embodiments, the tacky conductive material is configured to maintain electrical contact between a shield structure and a penetrating foreign object during its penetration through the shield structure comprising the electrode shield, the counterelectrode shield, or any combination thereof. In some embodiments, the shield structure is configured to maintain dimensional stability and / or mechanical integrity, during penetration by a foreign object. In some embodiments, the shield structure is configured to allow electrical discharge to initiate electrical conductance between the electrode shield and the counter-electrode shield. In some embodiments, the shield structure is configured for a uniform surface with low variability in thickness and / or resistivity, such that electrical conductance is initiated between the electrode shield and the counter-electrode shield. In some embodiments, the shield separator comprises an electrically insulating material. In some embodiments, the shield separator comprises a polymer, a resin, any plurality of types thereof, or any combination thereof. In some embodiments, the shield separator is (e.g., substantially) devoid of open pores. In some embodiments, the shield separator comprises open pores. In some embodiments, the open pores are configured to allow migration of charge carriers therethrough. In some embodiments, the shield separator comprises a discrete layer, a laminated structure, a dielectric, any plurality of types thereof, or any combination thereof. In some embodiments, the shield separator is disposed between the electrode shield and the counter-electrode shield within the gap. In some embodiments, a housing encloses the cell assembly, the housing comprising the shield separator. In some embodiments, the housing comprises one or both of the electrode shield and the counterelectrode shield. In some embodiments, the housing comprises one or both of the electrode shield and the counter-electrode shield as laminated components by an electrically insulating laminate. In some embodiments, the electrode shield and the counter-electrode shield, (A) are disposed outside of the cell assembly and / or (B) are configured to cause discharge of electrical energy resulting from a foreign object penetration to occur outside the cell assembly, the discharge being initiated between the electrode shield and the counterelectrode shield. In some embodiments, the discharge occurs within the gap between the electrode shield and the counter-electrode shield, before the foreign object reaches the cell assembly. In some embodiments, the foreign object discharges at least about 50% of the electrical energy before reaching the cell assembly at least in part by connecting the electrode shield and the counter electrode shield. In some embodiments, the foreign object discharges at least about 70%, 80%, 90%, or 95% of the electrical energy before reaching the cell assembly. In some embodiments, the foreign object discharges the electrical energy before reaching the cell assembly at least in part by connecting the electrode shield and thecounter electrode shield, such that a thermal runaway reaction does not occur in the cell assembly during, or as a result of, penetration of the foreign object into the cell assembly.

[0017] In another aspect, a method of testing any of the above devices, the method comprising: (a) providing the device; and (b) inserting the foreign object into the device such that the foreign object (i) penetrates the electrode shield and the counter electrode shield on its way to the cell assembly and (ii) penetrates the cell assembly.

[0018] In another aspect, an apparatus for testing any of the above devices, the apparatus comprising at least one controller configured to direct one or more operations for assembling any of the above devices, the operations comprising: (a) providing the device; and (b) inserting the foreign object into the device such that the foreign object (i) penetrates the electrode shield and the counter electrode shield on its way to the cell assembly and (ii) penetrates the cell assembly. In some embodiments, the at least one controller is operatively coupled with wiring, to a wireless communication system, to a power source, and / or to a communication network. In some embodiments, the at least one controller is operatively coupled with one or more sensors configured to measure one or more parameters of the testing. In some embodiments, the one or more sensors comprise proximity sensors, electrical current sensor, temperature sensor, resistance sensor, voltage sensor, pressure sensor, any plurality of types thereof, or any combination thereof. In some embodiments, the at least one controller utilizes data collected from the one or more sensors for the testing. In some embodiments, the at least one controller utilizes the data collected from the one or more sensors to stop the testing.

[0019] In another aspect, non-transitory computer-readable program instructions physically inscribed on at least one medium, the program instructions, when read by one or more processors operatively coupled with any of the above devices, cause the one or more processors to execute one or more operations for preparing any of the above devices, the one or more operations comprising: (a) providing the device; and (b) inserting the foreign object into the device such that the foreign object (i) penetrates the electrode shield and the counter electrode shield on its way to the cell assembly and (ii) penetrates the cell assembly. In some embodiments, the one or more processors are operatively coupled with one or more sensors configured to measure one or more parameters of the testing. In some embodiments, the one or more sensors comprise proximity sensors, electrical current sensor, temperature sensor, resistance sensor, voltage sensor, pressure sensor, any plurality of types thereof, or any combination thereof. In some embodiments, the one or more operations are configured to direct the one or more processors to utilize data collected from the one or more sensors for the testing. In some embodiments, the one or more operations are configured to direct the one or more processors to utilize the data collected from the one or more sensors to stop the testing.

[0020] In another aspect, a method of manufacturing any of the above devices, the method comprising: (a) providing components the cell assembly; and (b) electrically coupling the electrode shield with the cell assembly at least in part by coupling the electrode shield with the electrode terminal tab.

[0021] In another aspect, an apparatus for manufacturing any of the above devices, the apparatus comprising at least one controller configured to direct one or more operations for assembling any of the above devices, the operations comprising: (a) providing the cell assembly; and (b) electrically coupling the electrode shield with the cell assembly at least in part by coupling the electrode shield with the electrode terminal tab. In some embodiments, the at least one controller is operatively coupled with wiring, to a wireless communication system, to a power source, and / or to a communication network.

[0022] In another aspect, non-transitory computer-readable program instructions physically inscribed on at least one medium, the program instructions, when read by one or more processors operatively coupled with any of the above devices, cause the one or more processors to execute one or more operations for preparing any of the above devices, the operations comprising: (a) providing the cell assembly; and (b) electrically coupling the electrode shield with the cell assembly at least in part by coupling the electrode shield with the electrode terminal tab.

[0023] 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.

[0024] 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.

[0025] 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).

[0026] 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).

[0027] 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).

[0028] 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 toimplement (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.

[0029] 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.

[0030] 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).

[0031] 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.

[0032] 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-transitorycomputer-readable medium is operatively coupled with the mechanism. In some embodiments, the mechanism comprises an apparatus or an apparatus component.

[0033] 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 machine-executable 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).

[0034] 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.

[0035] 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.

[0036] 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 non-volatile 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.

[0037] 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.

[0038] In some embodiments, the program instructions are of a computer product.

[0039] 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.

[0040] Additional aspects and advantages of the present disclosure will become readily apparent to those skilled in this art from the following detailed description, wherein only illustrative embodiments of the present disclosure are shown and described. As will be realized, the present disclosure is capable of other and different embodiments, and its several details are capable of modifications in various obvious respects, all without departing from the disclosure. Accordingly, the drawings and description are to be regarded as illustrative in nature, and not as restrictive.INCORPORATION BY REFERENCE

[0041] 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.

[0042] 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

[0043] 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.

[0044] The novel features of the present disclosure are set forth with particularity in the appended claims. Each of the figures disclosed herein is shown in accordance with some implementations of the subject matter of the disclosure. A better understanding of the features and advantages of the present disclosure will be obtained by reference to the following detailed description that sets forth illustrative embodiments, in which the principles of thepresent disclosure are utilized, and the accompanying drawings or figures (also “Fig.” and “Figs.” herein), of which:

[0045] Fig. 1 depicts a schematic example of various cells;

[0046] Fig. 2 depicts schematic examples of folding options for energy manipulation device (e.g., battery) components, and a current collector;

[0047] Fig. 3 depicts schematic examples of devices (e.g., batteries) and cells;

[0048] Fig. 4 depicts schematic examples of cell architectures;

[0049] Fig. 5 depicts schematic exploded views of device (e.g., battery) components;

[0050] Fig. 6 depicts perspective views of device (e.g., battery) components;

[0051] Fig. 7 shows images of device (e.g., battery) components in cross sectional views;

[0052] Fig. 8 shows pre-charging (e.g., buffering) of a cell assembly

[0053] Fig. 9 illustrates foreign object penetration path into a construct;

[0054] Fig. 10 illustrates four structural configurations of constructs having variations in shield- coupled electrode geometry;

[0055] Fig. 11 illustrates four structural configurations of constructs having varying enclosure relationships;

[0056] Fig. 12 is an illustrative view of a secondary battery cell wrapped with a metal foil, in accordance with some implementations of the subject matter of the disclosure;

[0057] Fig. 13 is an illustrative view of a nail penetration safety test setup with a secondary battery cell with a metal wrap, in accordance with some implementations of the subject matter of the disclosure;

[0058] Fig. 14 is an illustrative view of a copper foil on a double-sided tape to be used on a secondary battery cell wrapped with a metal foil, in accordance with some implementations of the subject matter of the disclosure;

[0059] Fig. 15 illustrates a method for fabricating an electrode construct comprising shields;

[0060] Fig. 16 is an illustrative flowchart of a process for manufacturing a secondary battery cell having a metal foil, in accordance with some implementations of the subject matter of the disclosure;

[0061] Fig. 17 depicts a schematic example of a control system; and

[0062] Fig. 18 depicts a schematic example of a processing system.

[0063] 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

[0064] 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 alternativesto the embodiments of the invention described herein might be employed. The various embodiments, aspects, examples, variations, alternates, and instances, disclosed herein are combinable, as appropriate.

[0065] 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.

[0066] 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.

[0067] An immediately consecutive second feature to a first feature is devoid of another feature disposed therebetween, the features being of the same type. The feature can be a real-life feature, a calculated feature, or any other virtual feature.

[0068] 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.

[0069] The conjunction “and / or” as used herein in “X and / or Y” - including in the specification and claims - is meant to include the options (i) X, (ii) Y, and (iii) X and Y, as applicable. The phrase “including X, and / or Y” is meant to have the same meaning as the phrase “comprising X or Y” under currently prevailing US law.

[0070] 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 physicalor non-physical coupling. The non-physical coupling may comprise signal-induced coupling (e.g., wireless coupling).

[0071] 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.

[0072] The symbol “*” designates the mathematical operation of multiplication, e.g., “times.”

[0073] 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.

[0074] 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.

[0075] While the disclosure refers to a cathode as an electrode, the electrode may be an anode, as applicable.

[0076] While various portions herein may refer for simplicity to a battery as an energy storage device, that disclosure is extended to any another energy storage device, as applicable.

[0077] As noted above, implementations of the present disclosure can relate to (e.g., secondary) batteries, the structures that make up the (e.g., secondary) batteries, and the methods and processes for manufacturing the structures and batteries. As used herein, the term “anode” used in the context of a (e.g., secondary) battery may refer to the negative electrode in a (e.g., secondary) battery. “Anode material” or “anodically active” as used herein may refer to a material or materials suitable for use as the negative electrode of a (e.g., secondary) battery. The term “cathode” as used herein in the context of a (e.g., secondary) battery may refer to the positive electrode in a (e.g., secondary) battery. “Cathode material” or “cathodically active” as used herein may refer to a material or materials suitable for use as the positive electrode of a (e.g., secondary) battery.

[0078] In some implementations described herein, the term “electrode” may be used to refer to either the anode or the cathode, and the term “counter-electrode” may refer to the other or opposite. For the sake of explanation, implementations may be described in terms of “electrode” and “counter-electrode.” It should be appreciated that in these implementations, the term electrode may be replaced by the term anode while the term counter-electrode may be replaced by the term cathode, as applicable. Alternatively, in these implementations, the term electrode may be replaced by the term cathode while the term counter-electrode may be replaced by the term anode, as applicable.

[0079] In some embodiments, the energy manipulation device may comprise at least one battery. The battery may comprise one or more cells. The battery may be a rechargeable battery, e.g., a secondary battery. The charge carriers of the battery may comprise alkali earth, alkali cations, a plurality of types of any thereof, or any combination thereof. In an example, the battery comprises charge carriers such as lithium charge carriers.

[0080] In some embodiments, the energy manipulation device may comprise at least one battery. The battery may comprise one or more cells. The battery may be a rechargeable battery, e.g., a secondary battery. The charge carriers of the battery may comprise alkali earth, alkali cations, a plurality of types of any thereof, or any combination thereof. In an example, the battery comprises charge carriers such as lithium charge carriers. In some embodiments, charge carriers may comprise carrier ions. In some embodiments, carrier ions are provided to positive electrodes and / or negative electrodes by carrier ion supply layers. Carrier ion supply layers may comprise one or more sources of lithium ions, sodium ions, potassium ions, calcium ions, magnesium ions, aluminum ions, and / or similar such ions. The battery may or may not be a polymer type battery such as a lithium polymer type battery.

[0081] In some embodiments, the energy manipulation device includes at least one-unit cells. The energy manipulation device may comprise a population of unit cells (e.g., also referred to herein as a “set of cells”). The device may comprise an electrode connector operatively coupled with the electrode and a counter-electrode connector operatively coupled with the counter-electrode, with operatively coupled comprising electrically connected. The electrode connector may be also referred to herein as “an electrode terminal,” and the counter-electrode connector may be also referred to herein as “a counter-electrode terminal.” The device may comprise an electrode busbar, a counter-electrode busbar, an electrode terminal operatively coupled with the electrode busbar, and a counter-electrode terminal operatively coupled with the counter-electrode busbar. The electrode and counter electrode of the unit cell are separated by each other by a gap, e.g., to electrically separate the electrode from the counterelectrode. The gap may include a separator to (a) electrically isolate the electrode from the counter electrode and (b) allow traversal of charge carriers through the separator. In some embodiments, each unit cell of the set of cells, includes an electrode structure and a counterelectrode structure separated from each other by a gap. One or more (e.g., each) cells of the set of cells, each include a separator disposed in the gap. In some embodiments, the battery includes adjacent electrode sub-units. Each of the electrode sub-units has a dimension in the X-axis, Y-axis and Z-axis, respectively. The X-axis, Y-axis and Z-axis are each mutually perpendicular, akin to a Cartesian coordinate system. As used herein, dimensions of each electrode sub-unit in the Z-axis may be referred to as a "height", dimensions in the X-axis may be referred to as a "length" and dimensions in the Y-axis may be referred to as a "width." The electrode sub-units may be combined into one or more unit cells. A cell can include (a) at leastone anodically active material mass (e.g., layer) and / or (b) at least one cathodically active material mass (e.g., layer). In some embodiments, the anodically active material is separated from the cathode by the gap. In some embodiments, the cathodically active material is separated from the anode by the gap. In some embodiments, the cathodically active material is separated from the anodically active material by the gap. The set of cells may comprise at least 2, 10, 20, 50, 100, 150, 200, 250, or 500 cells. The set of cells may comprise any number of cells between any of the aforementioned number of cells, e.g., from 2 to 500 cells, or from 50 to 500 cells. An active material mass may operatively couple to a current collector. The active material mass may comprise one or more layers. The active material may form a gradient

[0082] In some embodiments, the device includes an electrode busbar and a counterelectrode busbar. The electrode busbar can be operatively coupled with (e.g., electrically connected with) the electrode, e.g., via electrode tab. The counter-electrode busbar is operatively coupled with (e.g., electrically connected with) the counter-electrode, e.g., via counter-electrode tab. The electrode busbar can be operatively coupled with the electrodes of the set of cells, e.g., via electrode tabs. The counter-electrode busbar is operatively coupled with the counter-electrodes of the set of cells, e.g., via counter-electrode tabs. An electrode tab can be an extension of the electrode that is devoid of the electrode active material. A counter-electrode tab can be an extension of the counter-electrode that is devoid of the counter-electrode active material.

[0083] In some embodiments, the device includes a first busbar and a second busbar that are in electrical contact with the anode(s) and the cathode(s), respectively, e.g., via electrode tabs. The electrode tabs on the first side of the stack of cells can be electrically coupled with the first busbar, which may be referred to as an anode busbar. The electrode tabs on the second side of the stack of cells may be electrically coupled with the second busbar, which may be referred to as a cathode busbar. In some embodiments, the first busbar is electrically coupled with a first electrical terminal of the secondary battery, which is electrically conductive. When the first busbar comprises an anode busbar for the device (e.g., battery), the first electrical terminal comprises a negative terminal. In some embodiments, the second busbar is electrically coupled with a second electrical terminal of the device, which is electrically conductive. When the second busbar comprises a cathode busbar for the device, the second electrical terminal comprises a positive terminal of the device.

[0084] In some embodiments, the cell may be coupled with a (e.g., solid) busbar. In some embodiments, the set of cells may be coupled with the (e.g., solid) busbar. The busbar may comprise a (e.g., solid) material of a class. The material class may include an elemental metal, a metal alloy, or an allotrope of elemental carbon, any plurality of types thereof, or any combination thereof. In an example, the (e.g., solid) busbar may comprise a compositematerial and a non-composite material. The busbar may comprise any conductive material disclosed herein. In an example, the busbar includes copper (e.g., Cu101) and Inconel (e.g., N178). The material class can be an oxygen free material. The material class may be an electronic grade material.

[0085] 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). A contacting surface of the busbar is an exposed surface of the busbar face(s) to contract the (a) the tab(s), (b) any tacky connector, (c) any welding, or (d) any combination thereof. The (e.g., solid) busbar may comprise one or more perforations (e.g., holes). The perforation(s) may 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.

[0086] In some embodiments, the cell undergoes pre-loading with charge carriers, e.g., before its regular use. The pre-loading may comprise loading the cell with charge carriers, e.g., “pre- I ithiation” in the case of lithium cations being the charge carriers. The pre-loading (also referred herein as “buffering”) may be performed during manufacturing and / or before providing the battery for its intended use. The pre-loading may facilitate insertion of additional charge carriers for a charge carrier source such as a lithium source, into the electrode(s) of the battery such as into the anode(s). The electrode may be a vertically short electrode. The pre-loading may replenish (e.g., irreversible) loss of the charge carriers during formation of the battery, e.g., to increase (a) efficiency of the first cycle and / or (b) cell capacity. The pre-loading may result in a reservoir of the charge carriers within the cell, and / or smaller cycled voltage window. The pre-loading may improve current distribution, e.g., during fast charge. The pre-loading may improve the cycle life of the battery. Buffering or pre-loading may result in pressurization of the cell at its first charging cycle, e.g., due to loading of the anode with charge carriers such as lithium. The pressure adjuster described herein can aid in maintaining overpressure in the system without having to put pressure during buffering, e.g., the adjuster can establish a minimal / threshold overpressure in the device during formation without having to buffer the cell. A rough exposed surface of charge carrier plating may remain throughout the life of the battery, and may compromise function of the battery, e.g., due to depletion of charge carriers and / or due to causing a short (e.g., as a consequence of dendrite formation from an electrode to its counter electrode). In some examples, the geometry of a battery may include a side gap located adjacent to a cell, to enable electrolyte to flow into the gap during buffering.

[0087] In some embodiments, a cell comprises an electrode (e.g., reference electrode), a counter electrode, separated from each other by a gap, also referred to herein as “a separation space.” The separation space may comprise a separator, e.g., having a material comprisingconduits or pores, e.g., micro conduits, or micropores. The pores and / or conduits may 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 dividing space. The dividing space and the separating space may or may not have the same material content. A divider material may be disposed in the dividing space. The dividing material may or may not be of the same type of material as the separator. The separator may be (e.g., substantially) a plane, or a layer. The separator may be an ionically permeable microporous material suitable for use as a separator in an electrochemical cell. In some embodiments, the separator layer is coated with ceramic particles on one or both sides. In some embodiments, a cell includes an anode current collector in the center, which may comprise or be electrically coupled with, one of the electrode tabs on one of the sides of the secondary battery. In some implementations, the unit cell includes the anodically active material layer, the separator layer, the cathodically active material layer, and a cathode current collector in a stacked formation along a stacking axis. The cathode current collector may comprise a cathode tab devoid of cathode active material. The anode current collector may comprise an anode tab devoid of anode active material. The anode tab may be disposed at the same side of the cathode tab, or at a different side such as an opposing side.

[0088] In some embodiments, the cathode includes cathodically active material. The cathodically active material may include a cathodically active material including transition metal oxides, transition metal sulfides, transition metal nitrides, lithium-transition metal oxides, lithium-transition metal sulfides, lithium-transition metal nitrides, any plurality thereof, and / or any combination thereof. The cathodically active material may include transition metal elements of the transition metal oxides, transition metal sulfides, transition metal nitrides, any plurality thereof, and / or any combination thereof. The cathodically active material may include metal elements having a d-shell orf-shell. The cathodically active material may comprise metal element including Sc, Y, lanthanoids, actinoids, Ti, Zr, Hf, V, Nb, Ta, Cr, Mo, W, Mn, Tc, Re, Fe, Ru, Os, Co, Rh, Ir, Ni, Pb, Pt, Cu, Ag, Au, any plurality thereof, and / or any combination thereof. The cathodically active material may include lithium cobalt oxide (LiCoCh), LiNio.5Mn1.5O4, Li(NixCoyAlz)O2, lithium metal phosphate (e.g., lithium iron phosphate, LiFePO4), Li2MnO4, V2O5, molybdenum oxysulfides, phosphates, silicates, vanadates, sulfur, sulfur compounds, oxygen (air), lithium nickel manganese cobalt oxide (Li(NixMnyCoz)O2), any combinations thereof, and / or any plurality thereof. In some implementations, the cathode (e.g., cathodically active material) is selected from transition metal oxides, transition metal sulfides, transition metal nitrides, lithium-transition metal oxides, lithium-transition metal sulfides,transition-metal phosphates, lithium-transition-metal phosphates, and lithium-transition metal nitrides may be selectively used. The transition metal elements of these transition metal oxides, transition metal sulfides, and transition metal nitrides can include metal elements having a d-shell or f-shell. Specific examples of such metal element are Sc, Y, lanthanides, actinides, Ti, Zr, Hf, V, Nb, Ta, Cr, Mo, W, Mn, Tc, Re, Fe, Ru, Os, Co, Rh, Ir, Ni, Pb, Pt, Cu, Ag, and Au. Additional cathode active materials include LiCoO2, LiNio.5Mn1.5O4, Li(NixCoyAlz)O2, LiFePO4, Li2MnO4, V2O5, molybdenum oxysulfides, phosphates, silicates, vanadates, sulfur, sulfur compounds, oxygen (air), Li(NixMnyCoz)O2, and combinations thereof. The cathode active material may comprise, S (e.g., U2S in the lithiated state), LiF, Fe, Cu, Ni, FeF2, FeOdF3.2d, FeFs, C0F3, C0F2, CuF2, NiF2, where 0<d<0.5, metal oxides, metal sulfides, metal phosphates, binders, fillers, any plurality thereof, or any combination thereof. The filler may be inert to the chemistry of the device, e.g., chemistry of the cell. The binders may include polyvinylidene difluoride and / or polytetrafluoroethylene. The cathode may comprise LCO, NCM, LFP, LMO, Nickel, Lithium manganese Iron phosphate, lithium manganese iron phosphate, sodium-ion, nickel, manganese rich lithium, lithiated cobalt oxide, lithiated manganese oxide, lithiated nickel-manganese-cobalt oxide, any plurality of types thereof, or any combination thereof. The cathode (e.g., and the device) may be devoid of cobalt.

[0089] In some embodiments, the energy manipulation device may comprise a battery. The device may comprise Li-ion batteries, nickel metal hydride batteries, alkaline batteries, any plurality of types thereof, or any combination thereof. The battery may include a cell comprising Cu, Al, Ni, polyethylene, polypropylene, any derivatives thereof, any plurality of types thereof, or any combination thereof.

[0090] In some embodiments, the anode includes anodically active material. The anodically active material may include silicon (Si), germanium (Ge), tin (Sn), lead (Pb), antimony (Sb), bismuth (Bi), zinc (Zn), aluminum (Al), titanium (Ti), nickel (Ni), cobalt (Co), cadmium (Cd), any combination thereof, and / or any plurality thereof. The anodically active material may include alloys or intermetallic compounds including Si, C, Ge, Sn, Pb, Sb, Bi, Zn, Al, Ti, Ni, Co, Cd, any combination thereof, and / or any plurality thereof. The anodically active material may include alloys, and / or intermetallic compounds. The anodically active material may include oxides, carbides, nitrides, sulfides, phosphides, selenides, tellurides of Si, Ge, Sn, Pb, Sb, Bi, Zn, Al, Ti, Fe, Ni, Co, V, or Cd, any combination thereof, or any plurality thereof. The anodically active material may include mixtures (e.g., containing Lithium), composites (e.g., containing Lithium), any combination thereof, and / or any plurality thereof. The anodically active material may include salts (e.g., of Sn), hydroxides (e.g., of Sn), lithium titanate, lithium manganate, lithium aluminate, lithium-containing titanium oxide, lithium transition metal oxide, ZnCo2O4, particles of graphite, particles of carbon, metal form of the charge carriers (e.g.,lithium metal), any combinations thereof, and / or any plurality thereof. The anodically active material may be coated. The coating may comprise stabilized metal form of the charge carrier material (e.g., lithium metal particles). The particulate material may include lithium carbonate- stabilized lithium metal powder, lithium silicate stabilized lithium metal powder, other source of stabilized lithium metal powder or ink, any combination thereof, and / or any plurality thereof. The anode active material may comprise a material intercalating the charge carriers. The active material of the anode may include silicon and / or an allotrope of elemental carbon. The allotrope of elemental carbon may be any of the ones disclosed herein, e.g., active carbon, graphite, carbon fiber, carbon nanotube, amorphous carbon, and / or a fullerene. The tubular structures may comprise nested tubes, e.g., at least 2, or 3 nested tubes. The carbon fibers may be weaved, aligned (e.g., in parallel and / or at an angle relative to each other), randomly situated, or any combination thereof, as applicable. The anode may be a nearly 100% silicon - carbon anode. The silicon may be in the form of a silicon tube such as a nanowire, or nanotube, e.g., nested or non-nested. The anode may comprise particulate material. The anode may comprise a carbon scaffold on which silicon is deposited (e.g., layer of silicon). An exposed surface of the silicon may be coated by the, or by at least one other, of the allotropes of elemental carbon. The carbon may comprise black carbon. The carbon may include hard carbon and / or soft carbon. The carbon-silicon structure may comprise successive layers and / or scaffold. The carbon may comprise a particulate material. The particulate material may serve as a base for deposition of the one or mor layers. The particulate material may or may not include crevices. The one or more layers may be deposited onto an exposed surface of the crevices. Anodically active materials may comprise carbon materials such as graphite and soft or hard carbons, or graphene (e.g., single-walled or multi-walled carbon nanotubes), or any of a range of metals, semi-metals, alloys, oxides, nitrides, compounds capable of intercalating lithium, compounds forming an alloy with lithium, any plurality thereof, or any combination thereof. Specific examples of the metals or semi-metals that may be used as the anode material include graphite, tin, lead, magnesium, aluminum, boron, gallium, silicon, Si- C composites, Si / graphite blends, silicon oxide (SiOx), porous Si, intermetallic Si alloys, indium, zirconium, germanium, bismuth, cadmium, antimony, silver, zinc, arsenic, hafnium, yttrium, lithium, sodium, graphite, carbon, lithium titanate, palladium, mixtures thereof, any plurality thereof, or any other combination thereof. In some implementations, the anodically active material may comprise aluminum, tin, silicon, an oxide thereof, a nitride thereof, a fluoride thereof, other alloy thereof, any plurality thereof, or any combination thereof. In some implementations, the anodically active material may comprise silicon, an alloy thereof, a composite thereof, an oxide thereof, any plurality thereof, or any combination thereof. In some embodiments, the battery may be without an active material (e.g., simple cell).

[0091] In some embodiments, the energy manipulation device comprises an electrochemical cell. The cell may comprise an electrode and a counter-electrode separated from each other by a gap. The device may comprise a simple cell, e.g., comprising passive electrodes. The simple cell may comprise anode current collector, cathode current collector separated from the anode current collector by a gap, an electrolyte, and charge carriers. The cell may comprise partially active electrodes - one current collector contacting an active material mass. The mass can be a layer. The cell may comprise fully active electrodes - both electrode and counter-electrode current collectors of the cell, each contacting a respective active material mass, e.g., a layer.

[0092] In some examples, the energy manipulation device may comprise a fuel cell. In other examples, the energy manipulation device may comprise a primary battery, which may be a non-rechargeable battery. The primary battery may be a battery comprising Li metal, alkaline, zinc-carbon, silver-oxide, and / or any other suitable material. In some examples, the energy manipulation device may comprise a secondary battery, which may be rechargeable. The secondary battery may be a battery comprising Li ion, lead acid (lead dioxide with sulfuric acid), nickel cadmium, nickel metal hydride, and / or any other suitable material. The use of a secondary battery or rechargeable battery may enable a reduction in environmental waste, as the materials may be reused for multiple cycles as compared to a primary or non-rechargeable battery. In some examples, the energy manipulation device described herein may comprise an electrochemical cell. As noted above, the cell may include an anode material and a cathode material. In an example, an electrochemical cell comprises passive electrodes, wherein the simple electrochemical cell includes an anode charge carrier, a cathode charge carrier separated from the anode by a gap, an electrolyte and charge carriers. In some examples, the energy manipulation device may comprise one or more active electrodes, wherein one charge carrier is in contact with an active material mass. The active material mass can comprise (e.g., be deposited in a form of) a layer. In some examples, the energy manipulation device may comprise one or more fully active electrodes, wherein the electrode and / or counter electrode charge carriers of a cell each contact a respective active material mass, e.g., a layer. The active material mass is configured to operatively coupled with its respective current collector of the electrode. The current collector may have an electrical conductivity of at least about 103Siemens / cm (S / cm), 104S / cm, 105S / cm, or 106S / cm. The current collector may have an electrical conductivity between any of the aforementioned values, e.g., from about 103S / cm to about 106S / cm, or from about 105S / cm to about 106S / cm.

[0093] In some examples, the cell comprises an active material, a charge carrier, an electrolyte, any plurality of types thereof, or any combination thereof. The active material (e.g., mass such as layer) may be added to one side or to both sides of a cell or cell stack. In some embodiments, the electrode comprises a current collector (e.g., conductor) comprisingelemental metal, metal alloys, an allotrope of elemental carbon, any plurality of types thereof, or any combination thereof. The allotrope of elemental metal may comprise graphite, carbon nanotubes, carbon wires, fullerenes, hard carbon, soft carbon, active carbon, carbon black, acetylene black, Ketjen black, cylindrical carbon nanotubes, carbon fibers, any plurality of types thereof, or any combination thereof,. The nanotubes and / or nanowires, may be nested or non-nested. The cell may comprise charge carriers comprising salts such as lithium salts. The electrolyte material may comprise solid, semi-solid, liquid, any plurality of types thereof, or any combination thereof. The electrolyte materials may include salts, acids, and / or bases, e.g., dissolved in non-aqueous polar solvent(s). In some embodiments, the electrolyte may comprise a polymer-based electrolyte. The polymer-based electrolyte may include PEO- based polymer electrolyte, polymer-ceramic composite electrolyte, polymer-ceramic composite electrolyte, polymer-ceramic composite electrolyte, and / or similar such electrolytes.

[0094] In some embodiments, the electrolyte may include an oxide-based electrolyte (e.g., lanthanum titanate (Lio.34Lao.56TiO3), Al-doped lithium lanthanum zirconate (Li6.24La3ZrzAlo.24011.98), Ta-doped lithium lanthanum zirconate(Li6.4La3Zri.4Tao.6012), lithium aluminum titanium phosphate (Li.4Alo.4Tit.6(PO4)3), and / or similar such electrolytes. In some embodiments, the electrolyte may comprise a solid electrolyte (e.g., sulfide-based electrolyte such as lithium tin phosphorus sulfide (Li SnP2Si2), lithium phosphorus sulfide (13-U3PS4), lithium phosphorus sulfur chloride iodide (Li6PS5C1o.91o.i), and / or similar such electrolytes. The electrolyte may comprise ethylene carbonate, diethylcarbonate, dimethylcarbonate, ethylmethylcarbonate, propylene carbonate, any derivatives thereof, or any combination thereof.

[0095] Fig. 1 shows in example 100 a schematic representation of a cell, the cell comprising an electrode 102a - “C” (e.g., a cathode), and an opposing electrode which is a counter electrode 105a - “A” (e.g., an anode). A separator is disposed in separator space (e.g., gap) 103 - “B.” The battery cell is disposed in a battery having housing 109. The housing can be rigid, or flexible. The housing may include a rigid portion and / or a flexible portion. The battery can optionally have an insulator 104. The insulator may comprise one or more materials comprising a ceramic, a polymer, or a resin. The battery may comprise one or more insulator types. In an example, a polymer may fill a cathode gap, and alumina fills a cathode gap, the gap being from the edge of the cell to its immediately adjacent edge of the case (also herein “casing”). In some embodiments, insulator may comprise a non-electrically conductive material. The ceramic may comprise alumina (AI2O3), zirconia (ZnCh), magnesium oxide (MgO), boron nitride (BN), mullite, boehmite, or silicon carbide (SiC, e.g., in pure form). Under normal conditions during use of the battery, the main current is a load current 106 passing from one electrode to its opposing electrode, and through separation space 103. When volume104 comprises the insulator, the insulator contacts at least at opposing sides 102b and 102c of electrode 102a and at opposing sides 105b and 105c of counter-electrode 105a.

[0096] Fig. 1 shows in example 110 a schematic representation of a cell, the cell comprising an electrode 112 - “C” (e.g., a cathode), and an opposing electrode which is a counter electrode 115 - “A” (e.g., an anode). A separator is disposed in separator space 113 - “B.” The battery cell is disposed in a battery having housing 119. The separation space extends 121 beyond electrode 112, and extends 122 beyond counter electrode 115, the extension being along a long axis of each of the electrode, the long axis depicted in Fig. 1. The extension can extend longer in the lateral direction. The extension can form the tab. The battery has an insulator 114. Under the normal conditions, the load current 116 may be passing through separation space 113.

[0097] In some embodiments, the different extension distances of the components of the cell in the lateral direction, form a corrugated (e.g., misaligned) face of the cell, and thus a set of the cells, e.g., as depicted in Fig. 1 , 120 for a cell. The cell can comprise at least one uneven side, e.g., as is depicted in Fig. 1 , 120. The uneven (e.g., misaligned) side can create a wavy side of a set of cells.

[0098] Fig. 2 shows a schematic example 200 of a current collector in the form of a film or strip. The electrode active material may contact (e.g., be deposited onto) a conductive sheet, e.g., having a thickness of at most about 6 millimeters (mm), 5mm, 2.5mm, 1mm, or 0.5mm. The conductive sheet may be a foil, e.g., having a thickness of at most about 0.4mm, 0.2 mm, or 0.1mm. The current collector may comprise an internal portion, e.g., when assembled in the battery. The internal portion of the current collector contacts the active material of the electrode. The tab may be (e.g., substantially) devoid of the electrode active material. The current collector has a length axis and a width, and a height. The current collector has a face type having a largest surface area, the face type including sections 201 , and 202. The current collector has a length 203, a width 204, and a height 205. Section 202 designates the tab of the current collector that can bend upon assembly of the energy storage device such as to couple with a busbar, and section 201 designates the planar section of the current collector that can couple to an electrode active material, e.g., a powder with binder(s) and / or filler(s). In the example shown in 200, the tabs assume the same width 204 along their length. In some embodiments, the tabs contract (e.g., narrow such as taper) along their length, e.g., and along the longest axis 211. Longest axis 211 of the current collector intersects position 214 on a face of the electrode having height 205 and width 204, which face has the smallest surface area in the example of 200. The current collector has a shorter axis 212 normal to axis 211. The contraction of the tabs along axis 211 may be symmetrical about axis 211 , e.g., using a mirror symmetry, the mirror being along axis 211.

[0099] In some embodiments, the current collector may be an anode current collector. In some embodiments, the current collector may be a cathode current collector. The anode current collector may comprise a conductive material such as copper, carbon, nickel, stainless-steel, cobalt, titanium, and tungsten, and alloys thereof, or any other material suitable as an anode current collector layer. The current collector has an electrical conductivity of at least about 103 Siemens / cm, 104 Siemens / cm, or 105 Siemens / cm. The current collector has an electrical conductivity between any of the aforementioned values, e.g., from about 103 Siemens / cm to about 105 Siemens / cm. The cathode current collector may comprise aluminum, nickel, cobalt, titanium, and tungsten, or alloys thereof, or any other material suitable for use as a cathode current collector layer. In some embodiments, the cathode current collector comprises a metal such as aluminum, carbon, chromium, gold, nickel, NiP, palladium, platinum, rhodium, ruthenium, an alloy of silicon and nickel, titanium, or a combination thereof. In an example, a cathode current collector comprises gold or an alloy thereof such as gold silicide. By way of further example, in one embodiment, a cathode current collector comprises nickel or an alloy thereof such as nickel silicide.

[0100] Fig. 2 shows in example 250, a schematic vertical cross section of various batteries, showing arrangement and / or folding of battery cells with respect to a Cartesian coordinate system. In example 251 , battery cells are arranged parallel to each other. Examples 252-255 show various folding of a sheet comprising one or more battery cells, with 252 showing a zigzag fold, 253 showing a top hat fold, 254 showing a sinusoidal type fold, 255 showing a spiral (e.g., rolling) fold, and 256 an oval or oblong spiral (e.g., rolling) fold. The battery may comprise a battery cell folded in a wound (e.g., jelly roll) configuration having an oblong or cylindrical configuration.

[0101] In some embodiments, one or more cells are disposed within a housing (e.g., enclosure) to form the device, e.g., battery. The housing may insulate the battery from one or more reactive agents (also referred to herein as “reactive species”) in the ambient environment external to the device. The reactive agent(s) may comprise oxygen, water, alcohol, thiol, sulfuric acid, phosphoric acid, carboxylic acid, hydrogen sulfide, any plurality thereof, or any combination thereof. The reactive agent(s) may be oxygen based, sulfur based, and / or phosphorous based. The reactive agent(s) may include water and / or oxygen. In an example, the reactive agent(s) comprise water in a liquid and / or vapor form. The water may be in the form of droplets. The housing may separate and / or insulate the cell(s) from the reactive agent(s) present in the ambient environment external to the device, e.g., to curtail (e.g., hinder, or prevent) reactive agent(s) from reaching the cell such as including reaching the electrode(s) and any fuse of the device.

[0102] The energy manipulation device is of a (e.g., Euclidean) three-dimensional (3D) geometric shape. The device may have an asymmetrical shape, e.g., its housing may beasymmetrical in shape. The Euclidean 3D shape may comprise a cylinder or a prism. The prism may be a Euclidean prism, or an amorphous prism. In some embodiments, the battery is a prismatic battery. In some embodiments, the battery is a cylindrical battery. The battery may have a first FLS such as a height (e.g., Fig. 3, 331) of at least about 1 millimeters (mm), 2mm, 3mm, 5mm, 6mm, 8mm, or 10mm. The first FLS of the battery may be of any value between any of the aforementioned values, e.g., from about 1mm to about 10mm. The battery may have a second FLS such as a length (e.g., Fig. 3, 332) of at least about at least about 10 millimeters (mm), 50mm, 100mm, 150mm, or 200mm. The second FLS of the battery may be of any value between any of the aforementioned values, e.g., from about 10mm to about 200mm. The battery may have an aspect ratio of the second FLS to the first FLS of at least about 5:1 , 8:1 , 10:1 , 15:1 , 20: 1 , 25: 1 , 35: 1 , or 50: 1. The battery may have an aspect ratio of the second FLS to the first FLS between any of the aforementioned values, e.g., from about 5:1 to about 50:1.

[0103] Fig. 3 shows schematic perspective view examples of energy manipulation devices such as batteries and battery cell architectures therein, relative to a Cartesian coordinate system. Example 300 shows a cylindrical battery housing having a length 302 and height 301 , which is a diameter. The battery may comprise cell(s) that form a rolled sheet. In example 300, 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 330 shows a prismatic battery housing that is a rectangular prism, or a cuboid. The battery has length 332, height 331 , and width 333. Battery cells 335 are stacked in the battery along height 331 , and along the Z direction. In example 330, face XY has a larger surface area than face XZ, and face XY has a larger surface area than face YZ. Example 350 shows a prismatic battery housing that is a rectangular prism, or a cuboid. The battery has length 352, height 351 , and width 353. Battery cells 335 are stacked in the battery along length 352, and along the X direction. In example 350, face XY has a larger surface area than face XZ, and face XY has a larger surface area than face YZ.

[0104] In some embodiments, the cell is arranged (e.g., substantially) perpendicular to the face of a prismatic (e.g., cuboid) battery having the largest surface area. At times, the largest surface area face of the anode, the separation space, the separator, the cathode, and / or the dividing space, is disposed (e.g., substantially) normal to the face of the battery having the largest surface area. The anode, the separation space, any separator, and the cathode, may be arranged (e.g., substantially) parallel to each other. The cell components may be arranged about a stacking axis. The stacking axis may be parallel to the face of the housing (e.g., battery housing, enclosure, or casing) having the largest surface area. The stacking axis may be (e.g., substantially) normal to a face type of the electrode having the largest surface area. Fig. 3, 350 shows an example of battery cells, disposed normal to the XY face of the battery, whichXY face has the largest surface area among the battery’s faces. The surface area of the cell, in example 350, 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. 3, 350), 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. 3, 330) and / or to (b) cylindrical battery such as a wound cell (e.g., jelly roll) battery (e.g., Fig. 3, 300). In some embodiments, the greater the combined side (e.g., edge) surface area of the cells, the greater the residual current role is in the total current of the battery. When the cell comprises at least one uneven side, e.g., as is depicted in Fig. 1 , 120, the uneven (e.g., misaligned) side creates a wavy side of a set of cells. The wavy side may or may not contribute to the amount of residual current passing between an anode and a cathode of a cell, e.g., through the insulator.

[0105] In some embodiments, a shield-coupled electrode (SCE) and a shield-coupled counter-electrode (SCCE) may be used to protect the cell assembly, e.g., any of the electrochemical cell assemblies shown in Fig. 3. The SCE may be electrically coupled with a terminal tab of the electrode, e.g., the cathode. The SCE may be disposed externally to a housing (e.g., enclosure) enclosing the cell assembly. The SCCE may be electrically coupled with a terminal tab of the counter-electrode (e.g., anode). The SCCE may be disposed within the housing. The SCCE may be disposed at, or externally to, the housing. During penetration by a conductive foreign object, the SCE may be the first point of engagement with the foreign object traveling towards the cell assembly, e.g., a first point of electrical engagement if the foreign object is conductive. The shield (e.g., SEC and / or SCCE) may comprise an electrically conductive material mass, e.g., in a form of a block, a plank, a foil, a sheet, a wound structure, a layered structure, a non-layered structure, or any combination thereof as applicable. The SCE may include a tacky conductive interface. The tacky interface may maintain electrical contact during deformation. The tacky interface may be malleable (e.g., deformable) such as by being pulled by the foreign object such as upon interaction friction. The SCE and SCCE may together define a discharge path that redirects electrical discharge away from the cell core. The discharge may be formed (A) by the foreign object pushing the SCE towards the SCCE to a proximity sufficient to form a (e.g., arc and / or spark) discharge, and / or (B) by the foreign object being conductive, carrying the SCE charge, and approaching the SCCE at a proximity sufficient to form the arc. The electrical discharge may be formed (A) by the foreign object pushing the SCE towards the SCCE to a proximity sufficient for electrical discharge, and / or (B) by the foreign object being conductive, carrying the SCE charge, and approaching the SCCE at a proximity sufficient for electrical discharge. The SCE and SCCE configuration relative to each other and relative to the cell assembly, may be adapted for use with cylindrical,planar, or stacked cell assembly formats, e.g., to reduce the risk of thermal runaway during and penetration of the foreign object into the cell assembly.

[0106] In some embodiments, the device such as battery comprises battery cells. The battery cells may be stacked along an axis. A dividing space may be disposed between every two immediately adjacent cells such that a first cell contacts the first face of the dividing space, and a second cell contacts a second face of the dividing space opposing its first space. The dividing space may comprise an insulator, e.g., any insulator disclosed herein. The insulator may or may not comprise the dynamic insulator. The dividing space may electrically separate one cell from another. The stack of cells may follow a pattern; the pattern may comprise a sequence. The sequence may comprise an arrangement of components of the battery cell with respect to each other. The sequence may comprise an anode, a separation space, a cathode, and a dividing space. The sequence may follow a CBAS pattern, or a CBASABCS pattern, with “C” designating a cathode, “B” designating a separation space, “A” designating an anode, “S” designating the dividing space, and “E” designates an end plate, e.g., see Fig. 4. The cells may be stacked in one or more groups. The separation space may comprise two opposing faces. A face of the separation space contacting the anode, and an opposing face contacting the cathode. The cell may comprise components comprising an anode, a cathode, a separation space, and an optional dividing space. The dividing space may comprise the same type of material as the separation space. The dividing space and the separation space may be (e.g., substantially) the same. The components of the cell may be disposed along an axis. The components of the cell may be (e.g., substantially) symmetrically arranged along the axis, e.g., in mirror symmetry, the mirror plane running along the axis, and / or in a rotational symmetry, the rotational axis running along the cell stacking axis (e.g., parallel to axis 490 in Fig. 4). At least two components of the cell may extend in a direction (e.g., substantially) perpendicular to the cell stacking axis at a (e.g., substantially) same distance. At least two components of the cell may extend in a direction (e.g., substantially) perpendicular to the cell stacking axis (e.g., laterally) at a different distance from that axis. The different distance extension of the components can form a corrugated (e.g., misaligned) face of the cell, and of the set of cells, e.g., as depicted in Fig. 1 , 120. See also sides (e.g., edges) of cell sets in Fig. 4, 400, and 450. 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.

[0107] Fig. 4 shows a schematic cross-sectional example 400 of a battery comprising cathode 402, anode 405, separation space 403, and dividing space 407. The battery cells are disposed in volume 404 of the battery that can include an insulator such as a dynamic insulator. The battery cells are stacked along an axis 490, in a repeating CBAS arrangement. Each anode“A” in the battery is operatively coupled (e.g., connected) with a current collector such as 413, the anode current collectors being coupled in parallel to a main anode current collector 414, ending with cathode contact 411. Each cathode “C” in the battery is operatively coupled (e.g., connected) with a current collector such as 416, the anode current collectors being coupled in parallel to a main cathode current collector 417, ending with anode contact 412.

[0108] Fig. 4 shows a schematic cross-sectional example 450 of a battery comprising cathode 452, anode 455, separation space 453, and dividing space 457. The battery cells are disposed in volume 454 of the battery that can include an insulator such as a dynamic insulator. The battery cells are stacked along an axis 490, in a repeating CBASABCS arrangement. Each anode “A” in the battery is operatively coupled (e.g., connected) with a current collector such as 463, the anode current collectors being coupled in parallel to a main anode current collector 464, ending with cathode contact 461. Each cathode “C” in the battery is operatively coupled (e.g., connected) with a current collector such as 466, the anode current collectors being coupled in parallel to a main cathode current collector 467, ending with anode contact 462. In Fig. 4, 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.

[0109] In some embodiments, the battery comprises one or more main current collectors, e.g., as disclosed herein. The main current collector may include a busbar and / or a busbar extender. The main current collectors may or may not contact the insulator covering the edges of the cells. In the example shown in Fig. 4, 400, the main current collectors 417 and 414, are separated from the insulator 404 by a gap. In the example shown in 400, the main current collectors 417 and 414 contact the insulator 404.

[0110] 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. 4, 490). Fig. 4, 400 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 420 contacting the insulator at its opposing lateral ends. Fig. 4, 450 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 490.

[0111] 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, at least one type of an allotrope of elemental carbon may be used as currentcollectors. In an example, the metal alloy may comprise stainless steel. In an example, the allotrope of elemental metal may comprise carbon nanotubes, or carbon fibers. The tubular structures (e.g., nanotubes) may comprise nestled tubes, e.g., at least about 2, 3, 4, or more nestled tubes. The carbon fibers may be weaved, randomly dispersed, or any combination thereof. The strip of conductive material may or may not comprise a composite material. At least two cells in the energy storage device (e.g., battery) may be stacked in a direction (e.g., substantially) normal to their face having the largest surface area. The electrode has an electrode face having the largest surface area, and the counter-electrode has a counterelectrode face having the largest surface area. In some embodiments, there is a difference in a volume of the cell between a state of charge and a state of discharge of an electrode of the cell. The volume of the cell may repeatedly and / or reversibly alter between the state of charge and the state of discharge repeatedly. The reversible discharge may not be completely reversible, e.g., there may be an attrition in the properties of one or more components of the cell during a cycle of charge / discharge. The repeated cycling between the state of charge / discharge may comprise at least about 150 cycles, 200 cycles, 250 cycles, 300 cycles, 400 cycles, 500 cycles, 700 cycles, 800 cycles, 1000 cycles, 1200 cycles, or 1500 cycles. The repeated cycling between the state of charge / discharge may comprise any value of cycle between any of the aforementioned cycles, e.g., from about 150 cycles to about 1500 cycles. In some embodiments, there is a difference in a volume of the cell between a state of charge and a state of discharge of an electrode of the cell. The change in volume may comprise a change in at most about 20*, 25*, 50*, 100*, 200*, 300*, or 400* of an initial volume of the cell. The change in volume may comprise a change in at least about 10*, 25*, 50*, 100*, 200*, or 300* of an initial volume of the cell. The change in volume may comprise a change in any of the aforementioned 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.

[0112] The energy storage device may comprise at least one constraint (e.g., a brace, or a harness). The constraint may (e.g., substantially) maintain constant dimensions and / or volume of the device during the charge / discharge operations. The constraint may 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 5000PSI. 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.

[0113] In some embodiments, the battery cell set is disposed in an orthogonal stacked configuration.

[0114] In some embodiments, the device comprises a constraint system. The constraint system may be applied over one or both of the X-Y surfaces of the device (e.g., battery). In some embodiments, the constraint system includes a plurality of perforations to facilitate distribution (e.g., by flow of) an electrolyte solution after the cell, or cell set, has been assembled. In some embodiments, the casing comprises stainless steel (e.g., SS316, or SS301), aluminum, titanium, beryllium, beryllium copper (hard), copper (O2 free, and / or hard), nickel, other metals or metal alloys, composite, polymer, ceramic, any plurality thereof, any combination thereof, or any other suitable material as applicable.

[0115] Fig. 5 shows in example 500 an exploded view of a pair of constraints 501a and 501 b encasing a set (e.g., a population) of stacked battery cells 502, the pair of constraints being part of a constraint system. Example 550 shows an exploded view in which the two constraints 501 a-b are closer to the stacked cell set 502. Fig. 5 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. 5, the constraint can deter expansion of the cells anisotropically along the Y axis.

[0116] 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. 6, 631) of the face to a height (e.g., Fig. 6, 632) of that face. The cell may have an aspect ratio between any of the aforementioned values, e.g., from about 10:1 to about 50:1 , the aspect ratio being the length of the cell to the height. The cell may have an aspect ratio of at least about 5:1 , 8:1 , 10:1 , 15:1 , 20:1 , 25:1 35:1 , or 50:1 , the aspect ratio being a height (e.g., Fig. 6, 632) of the cell to a width (e.g., Fig. 6, 604, showing a width of three cells). The cell may have an aspect ratio between any of the aforementioned values, e.g., from about 5:1 to about 50:1 , the aspect ratio being the height of the cell to the width.

[0117] Fig. 6 shows in example 600 a lateral portion of three cells, each comprising an electrode such as 601 , a counter electrode such as 603, and a separator 602 disposed between each immediately adjacent pair of electrode and counter electrode. In example 600, the electrode (e.g., 601) extends less than the counter electrode 603 to the lateral edge 604 of the stacked cells, with the separator extending more towards the edge than the electrode, and then the counter-electrode, e.g., thus forming a corrugated, or wavy, lateral edge 604. Example 630 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.

[0118] Example 650 shows a set of stacked cells 651 enclosed by two opposing casings 652a and 652b. Current collectors of the stacked cells are coupled with connectors 653a and 653b. 653a connect to the electrodes of the set of cells, and 653b 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 655, 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. 6, casing 652a includes oblong openings, e.g., that are evenly spaced along the X direction. Fig. 6 is shown with respect to a Cartesian coordinate system.

[0119] Fig. 7 shows an example of vertical cross sections of various batteries with respect to a Cartesian coordinate system, viewed from a side having a length and a height (e.g., Fig. 3, height 351 and length 352), and depicted as a cross section. Example 700 shows battery cells such as cell 702 stacked in a direction normal to the z axis, the battery having housing 701. 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 toward the edges of the battery (e.g., along arrows 703), and in a direction along the stacking axis such as along 704. Constraints 707a and 707b are coupled with the cell stack to curb expansion. The constraints may limit displacement along the direction of arrows 703 and along 704. The constraints 707a-707b are disposed opposing each other and separated by a gap. Endplates 706a and 706b are disposed between the constraint and the cell stack. Each endplate may contact a distal end of the cell stack along the stacking direction. The endplates and the constraints may be arranged in a mirror symmetry about the stacking axis. The contraction and expansion may cause pressure buildup inside the battery. Heat may be generated during charge and discharge cycles (e.g., in interior of the cell stack along 704). The heat may be dissipated from the battery along arrows 703, increasing operational safety by reducing the risk of thermal runaway. Charge carriers generated from a precursor card may diffuse into the cell stack in the direction of arrow 705 (e.g., from locations corresponding toarrows 708). Diffusion of charge carriers may occur through perforations in the constraint system (e.g., perforation 651 of Fig. 6).

[0120] In some embodiments, one or more cells are enclosed in a rigid enclosure. The rigid enclosure may comprise the constraint system and / or endplates. The enclosure may comprise an elemental metal, a metal alloy, an allotrope of elemental carbon, a polymer, a resin, a plurality of types thereof, or any combination thereof. The housing may be made of a material with greater, lesser, or equal hardness compared to the enclosure. In an example, the housing may comprise a pouch having a lower hardness than a rigid enclosure such as a can. The pouch may be nested inside a harder housing (e.g., a can). A protective layer may be disposed between the enclosure and the housing, e.g., fig. 6, 635. The protective layer may comprise an elastic material, a polymer, a resin, a plurality of types thereof, or any combination thereof. The protective layer may form a band around the sides of the enclosure. The sides may include types with relatively smaller surface area. The protective layer may have a thickness, elasticity, and / or durability sufficient to cushion physical interaction between the housing and the enclosure. The protective layer may have a sponge-like geometry. The layer may be porous or non-porous. The protective layer may include polyurethane, polypropylene, polyethylene, and / or rubber. The layer may be attached to the enclosure by adhesion or by compression. The protective layer may be a pouch protective layer (PPL).

[0121] In an example, charge carriers and / or an electrolyte mixture are introduced into one or more cells from outside the cell assembly and within the housing. The entering materials may enter from outside the constraint system, outside the endplates, and / or from within the housing (e.g., pouch and / or can). Entry may occur from a seal, a surface of the housing, or a protective cell layer. Entry may occur by diffusion along a concentration gradient. When the starting material enters from a side of the battery having the largest surface area (e.g., top or bottom surface in example 650 of Fig. 6), diffusion may proceed inward toward the stack interior (e.g., towards 704 and opposing the directions of arrows 703 in Fig. 7). Entry may be faster when the stack includes elongated cell components with a high aspect ratio of height (e.g., 351) to width (e.g., 353), disposed along a face-parallel axis. Entry from a constraint-facing direction (e.g., 707a-707b) may provide faster access to the cell assembly’s center, than entry from a direction orthogonal to 703 (e.g., facing the wide surface of the electrodes).

[0122] Example 750 shows battery cell 752 rolled upon itself about an axis normal to the page (e.g., jelly roll configuration). Battery cell 752 is disposed in housing 751. During a charge and discharge cycle, the battery expands and contracts. Expansion generates force in the direction perpendicular to the roll axis and toward the battery edges (e.g., along arrows 753). One or more constraints may be added to control the expansion. The contraction and expansion may produce internal pressure. Heat may accumulate in stack interior 754. The heat may be released from the battery along arrows 753. The stacked cell layout shown in example 700may provide improved thermal conductivity compared to the rolled configuration of example 750. he stacked cell layout shown in example 700 may provide improved diffusion for the entering materials compared to the rolled configuration of example 750.

[0123] Fig. 8 illustrates, in example 800, an electrochemical cell assembly comprising a set of stacked electrodes 802 disposed between constraint portions, adjacent to which are charge carrier precursor cards 801a and 801 b. The constraint portions are positioned on opposite sides of the electrode stack along the X direction and are connected at their distal ends to maintain structural alignment and mechanical stability. The stacked electrodes 802 are oriented along a Y-axis stacking direction, with active material edges directed toward the X axis. A charge carrier source 801a and 801b is positioned adjacent to the edge of the electrode stack. Diffusion of charge carriers may occur from source 801a and 801b through perforations in constraint portions. The perforations may correspond to holes in constraint system, e.g., Fig. 5, 501a and 501b. The diffusion may proceed along the X direction to enter the stacked cells 802. The configuration may reduce inhomogeneous charge distribution and support direct interfacial delivery. The stacked cells 802 may be held by a constraint system such as that shown in Fig. 6, example 650. The stacked cells may span at least about 10 mm, 50 mm, 100 mm, or 200 mm along the Y direction. The stacked cells may span at most about 200 mm, 300 mm, 400 mm, or 600 mm along the Y direction. The stacked cells may span any value between any of the aforementioned values, e.g., from about 10 mm to about 500 mm along the Y direction. The stacked cells may span at least about 1 mm, 2 mm, 3 mm, or 5 mm along the X direction. The stacked cells may span at most about 5 mm, 6 mm, 8 mm, or 10 mm along the X direction. The stacked cells may span any value between any of the aforementioned values, e.g., from about 1 mm to about 10 mm along the X direction. The set of cells in the cell arrangement may comprise at least 2, 10, 20, 50, 100, 150, 200, 250, or 500 cells. The set of cells may comprise any number of cells between the aforementioned number of cells, e.g., from 2 to 500 cells, or from 50 to 500 cells. 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. 6, 631) of the face to a height (e.g., Fig. 6, 632) 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. 6, 632) of the cell to a width (e.g., Fig. 6, 604, showing a width of three cells).

[0124] In some embodiments, the battery is a rechargeable battery. The battery may undergo cycles of charge and discharge, with one cycle including one change and one discharge operation. The capacity of the battery to store and / or release electrical charge may diminish over the number of cycles it undergoes, e.g., at least in part due to various chemical reactions occurring in the battery during cycling. The reactions may comprise depletion of essentialcomponents such as essential chemical(s) for the function of the battery, e.g., depletion of the charge carriers.

[0125] In some embodiments, the energy manipulation device (e.g., battery) contains critical component(s) required for operation of the cell. The component may comprise a chemical. The critical components may initially be in optimized relative amounts in the battery. Some of the component(s) may enhance some performance attribute(s) while diminishing other attribute(s), e.g., making other attributes worse.

[0126] For example, during charging of a cell, charge carriers move from the cathode to the anode. When charge carriers (e.g., lithium cations) come into contact with a starting material (e.g., FEC) they undergo a reduction reaction and form a stable solid electrolyte interphase (SEI) layer on the anode’s surface. The SEI layer (e.g., significantly) improves the cycling stability of the batteries such as by preventing electrolyte decomposition, e.g., on the anode surface. Although formation of the SEI layer is requested for the stability of the battery, some of the starting materials (e.g., FEC) and the charge carriers become irreversibly bound, and thus removed from the cyclic operation of the battery, e.g., the rechargeable battery. Problems can arise due to the expanding and contracting of the electrode active material such as of the anode. In an example, the SEI layer is formed during charging, when the anode is expanded to a first size. As the battery discharges, the anode contracts to a second smaller size. In some examples, the SEI layer is not sufficiently elastic and as the anode contracts, the SEI layer cracks and / or breaks, thus exposing portions of the anode active material. Such problem may be exacerbated in batteries with electrodes comprising materials (e.g., Si, SiOx, Si-C, or any combination thereof), e.g., that have large volume differences between their charged and discharged states. The silicon content in the electrode may be at least about 20%, 40%, 50%, 80%, 90%, 95%, 97%, 98%, or 99%. The silicon content in the electrode may be between any of the aforementioned percentages, e.g., from about 20% to about 99%, or from about 80% to about 99%. In the next charging cycle, the SEI layer may become mended (e.g., clogged) to fix the cracks in the SEI layer caused in the previous cycle. Mending the SEI layer may require additional starting material amount (e.g., FEC), e.g., and charge carriers. In such scenario, the cycle of charging and discharging the battery may result in continual consumption of the starting materials, e.g., and of charge carriers. Buffering may be used to replenish the consumed charge carriers in such case.

[0127] In some embodiments, charge carriers (e.g., Li ions) reside in a cathode when the battery is in a discharged state, and reside in the anode when the battery is in a charged state. For example, when a battery charges, charge carriers (e.g., carrier ions) migrate into one or more electrode active materials. As the charge carriers traverse (e.g., move) in and out of the active material of the electrodes, the active material undergoes a volume change. The movement in an out of the active material may be referred to as ingress and egress of thecharge carriers relative to the active material. The amount of expansion may differ depending on the active materials used for the electrode. For example, a graphite electrode may expand by about 6% to 10% when the graphite electrode is charged. In another example, a silicon electrode may expand up to 300% when the silicon electrode is charged. In another example, a silicon oxide electrode may expand up to 210% when the silicon oxide electrode is charged. In another example, an electrode comprising silicon may expand up to about 20%, 50%, 75%, 100%, 200%, 300%, or 350% when the silicon electrode is charged, the percentage being volume per volume. In some embodiments, graphite electrodes require less starting material (e.g., fluoroethylene carbonate (FEC)) than silicon electrodes because the graphite electrodes expand less.

[0128] 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 carbon. 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 carbon may comprise carbon nanotubes, or carbon fibers. The tubular structures (e.g., nanotubes) may comprise nestled tubes, e.g., at least about 2, 3, 4, or more nestled tubes. The carbon fibers may be weaved, randomly dispersed, or any combination thereof. The strip of conductive material may or may not comprise a composite material. At least two cells in the energy storage device (e.g., battery) may be stacked in a direction (e.g., substantially) normal to their face having the largest surface area. The electrode has an electrode face having the largest surface area, and the counter-electrode has a counterelectrode face having the largest surface area. In some embodiments, there is a difference in a volume of the cell between a state of charge and a state of discharge of an electrode of the cell. The volume of the cell may repeatedly and / or reversibly alter between the state of charge and the state of discharge repeatedly. The reversible discharge may not be completely reversible, e.g., there may be an attrition in the properties of one or more components of the cell during a cycle of charge / discharge. The repeated cycling between the state of charge / discharge may comprise at least about 200 cycles, 500 cycles, 800 cycles, 1000 cycles, 1200 cycles, or 1500 cycles. In some embodiments, there is a difference in a volume of the cell between a state of charge and a state of discharge of an electrode of the cell. The change in volume may comprise a change in at most about 20%, 25%, 50%, 100%, 200%, 300%, or 400% of an initial volume of the cell. The change in volume may comprise a change in at least about 10%, 25%, 50%, 100%, 200%, or 300% of an initial volume of the cell. Thechange in volume may comprise a change in any of the aforementioned values, e.g., from about 10% to about 400%, from about 100% to about 400%, or from about 20% to about 200%. The charge carriers may interact with the active material (e.g., comprising silicon) such as in an intercalation and / or alloying process (e.g., Li-Si alloying). The Li-Si alloying may form alloys comprising LiisSi4 or Li22Sis. The lithium alloying of silicon may allow silicon to store at least 5*, 10*, or 15* more lithium as compared to graphite, with the operation “*” designating the mathematical operation of “times.”

[0129] In an example, a passivation layer is formed during operation of the device (e.g., during buffering) that consumes charge carriers and soluble passivating material in the cell. Portions of the passivation layer may be (e.g., additionally) formed during regular operation of the device, e.g., during charging and discharging cycles.

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

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

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

[0133] In some embodiments, the cell comprises an electrolyte mixture. The electrolyte mixture may comprise salt, solvent, additive, any plurality of types thereof, or any combination thereof. The electrolyte mixture may be non-aqueous. The electrolyte mixture may comprise an organic mixture. The electrolyte may comprise polar molecule. The electrolyte may be sufficiently polar to dissolve the charge carriers such that they are readily available to participate in the charge and / or discharge cycles. The electrolyte may be such that side reaction with any other device components are minimized, e.g., during the prescribed lifetime of the device and / or int eh prescribed conditions of the device. The salt may comprise a halogen salt, a borate salt, an imide salt, a sulfonyl salt, any derivatives thereof, or any combination thereof. In the case of Lithium charge carrier, the salt may comprise Lithium hexafluorophosphate (LiPFe), Lithium tetrafluoro borate (LiBF4), Lithium bis(fluorosulfonyl)imide (LiFSI), any derivatives thereof, or any combination thereof. The solvent may comprise a carbonate, a propionate, an ethyl acetate, any derivatives thereof, or any combination thereof. The solvent may compromise Ethylene carbonate (EC), Propylene carbonate (PC), Ethyl methyl carbonate (EMC), Diethyl carbonate (DEC), Propyl Propionate (PP), Ethyl Propionate (EP), Difluoro ethyl acetate (DFEA), or Methyl (2,2,2-trifluoroethyl) carbonate (FEMC), any derivatives thereof, or any combination thereof. The additive may comprise a carbonate, a nitrile (e.g., mono, bi, and / or thri- nitrile), a cyanide, an ethoxy, an ethylene, a sultone, any derivatives thereof, or any combination thereof. The additive may comprise fluoroethylene carbonate (FEC), Vinylene carbonate (VC), Vinyl ethylene carbonate (VEC), Succinonitrile (SN), adiponitrile (AN), 1 ,3,6-hexanetricarbonitrile (HTCN), 1 ,2-Bis(2- cyanoethoxy) ethane (DENE), propane sultone (PS), 1 ,3-propene sultone (PRS), any derivatives thereof, or any combination thereof.

[0134] In some embodiments, the cell comprises an anode separated by a gap from an anode. The cell may comprise a separator disposed in the gap. The cells may be elongated, e.g., may assume a shape of an elongated box. The face of the cell opposing the largest surface area face of the electrode (e.g., anode or cathode) may have an aspect ratio of at least about 10:1 , 15:1 , 20:1 , 35:1 , or 50:1 , the aspect ratio being a length of the face to a height 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 of the cell to a width.

[0135] In some embodiments, the architecture of the device comprising the stacked electrodes described herein (e.g., Figs. 3-8) allows for better (e.g., faster and / or homogenous) distribution of starting materials (e.g., FEC) into the cell, as compared to other cell arrangements. The other cell arrangements may include a folded (e.g., jelly roll) cell configuration, or cell having a smaller aspect ratio, e.g., and having vertically stacked electrodes. In an example, when the electrodes have a large aspect ratio - are elongated, (e.g., and are stacked such along a horizontal axis such as in Fig. 3, 350), starting materials introduced at the long edges of the electrodes (e.g., top and / or bottom of the device), may quickly reach the middle of the electrode height (e.g., 350), e.g., since the distance to the interior of the cell structure is shorter, e.g., relative to a situation in which the starting material(s) is / are introduced (A) at the side edges of an elongated cylinder (e.g., 300), or (B) at edges of electrodes having a smaller aspect ratio (e.g., and that are stacked along a vertical axis Fig. 3, 330).

[0136] In some embodiments, an electrochemical cell assembly comprises an electrode and a counter-electrode, e.g., a cathode and an anode. The cathode may be the positive terminal. The cathode may comprise a cathodically active material. The anode may be the negative terminal. The anode may comprise an anodically active material. The term electrode may refer to either anode or cathode. The term counter-electrode may refer to the opposing electrode, as defined elsewhere herein. The terminology may describe structural and / or polarity-based assignment depending on the configuration. In some embodiments, references to electrode structures define relative roles. The same physical structure may represent (i) an anode coupled with a shield-coupled counter-electrode (SCCE) and / or (ii) a cathode coupled with a shield-coupled electrode (SCE). The electrode designation may alternate based at least in part on (i) current direction, (ii) terminal polarity, and / or (iii) role assignment in the construct. Terminology may be mapped to match system-specific definitions. The construct may comprise the cell assembly, the SCE, the SCCE, and the housing (e.g., enclosure).

[0137] In some embodiments, the shield comprises a conductive material selected based at least in part on physical and / or electrical characteristics. The shield may include a SCE and / or the SCCE. The conductive material may comprise an elemental metal, a metal alloy, an allotrope of elemental carbon, any plurality of types thereof, or any combination thereof. Themass may be in the form of a sheet (e.g., a foil), a layered structure, a non-layered structure, a sponge, or any combination thereof. The conductive material may comprise a solid, or a semi-solid. The conductive material may include a malleable, ductile and / or tacky material. The conductive material may comprise (i) aluminum, (ii) copper, (iii) a metal alloy, (iv) a composite conductor (v) a plurality of types thereof and / or (vi) a combination thereof. The geometry of the conductive mass structure, may vary in (i) thickness, (ii) width, and / or (iii) effective coverage. The parameters of the conductive mass may be adjusted to control (i) arc localization, (ii) shield compliance, and / or (iii) compatibility with pouch constraints.

[0138] In some embodiments, the fabrication process for the shielded electrochemical device is modular and / or adaptable. The operations may be (i) omitted, (ii) combined, (iii) reordered, and / or (iv) supplemented. The operations may comprise (i) packaging operations, (ii) material validation, (iii) thermal barrier addition, and / or (iv) alignment tuning. The operations may be applied across (i) multiple configurations, (ii) in series, and / or (iii) in parallel. The method for fabrication may be compatible with real-time processing and / or modified assembly environments. The method of fabrication may comprise a roll-to-roll process.

[0139] In some embodiments, the construct comprises a shield-coupled electrode (also referred to as “SCE” herein) and a shield-coupled counter-electrode (also referred to as “SCCE” herein). The SCE may be disposed outside a sealed enclosure and / or electrically coupled with an electrode (e.g., cathode) terminal. The SCCE may comprise a constraint structure and / or be electrically connected with a counter-electrode (e.g., anode) terminal. A foreign object may penetrate the structure and / or engage the shielded regions sequentially. The object may form a discharge event such as an arc discharge event, between the two shield-coupled electrodes. The discharge may be between the electrode shield and the counter electrode shield, facilitated by the foreign object. The facilitation by the foreign object may include bringing the electrode shield sufficiently close to the counter-electrode shield to form the discharge: directly, though a tacky conductor (also herein “tacky conductive interface”), through the foreign object, or any combination thereof. The sealed enclosure may enclose the electrolyte, the cell assembly, and optionally the SCCE such as when it is in the form of a constraint system. Discharge (e.g., in the form of an arc closure) may occur externally and / or internally to the enclosure, e.g., depending on the location of the SCE-SCCE electrode pair. Shield placement may modulate the spatial location and / or thermal impact of the discharge on the cell assembly. The arrangement may delay direct cell breach and / or enable passive redirection of fault energy, e.g., without altering the cell’s electrochemical structure.

[0140] Example 900 of Fig. 9 illustrates an electrolytic assembly. A foreign object 905 is positioned above a shield-coupled electrode (SCE) 901 and is directed towards cell assembly having active material 919. The SCE 901 comprises a tacky interface and is electrically connected with one terminal tab (e.g., cathode terminal tab). A sealed enclosure (e.g., pouch)903 is located between the SCE 901 and the cell assembly enclosed by enclosure 903Enclosure 903 encloses. The cell assembly includes stainless steel constraint portions 902a and 902b coupled with two endplates such as endplate 904. The constraint portions 902a and 902b form a shield-coupled counter-electrode (SCCE) electrically coupled with the counter electrode (e.g., anode) terminal tab. The SCCE is positioned within enclosure 903. The structural components are arranged along a penetration path. The layered arrangement introduced in example 900 defines the sequential regions encountered by foreign object 905 during penetration. Each of examples 900, 920, and 940 represent a distinct stage of progression through the structure. Example 900 corresponds to the condition in which the foreign object contacts the SCE and the outer conductive layers. If foreign object 905 is conductive, the foreign object carries charge of the electrodes of the cell assembly by virtue of contacting the SEC that contacts the electrode terminal tab that is connected to the electrodes of the cell assembly. SEC 901 includes sequentially alternative (e.g., interlaced) layers of conductive material 906a and conductive tacky interface 906b. Conductive material 906a may be harder than tacky interface 906b. As foreign object 905 penetrates through SCE 901 , it may puncture, tear, and / or break the harder material 906a, and carry with him (e.g., by adhesion and / or friction) the tacky conductive interface 906b, thus carrying the electrode charge along penetration of foreign object 905. If the foreign object 905 is conductive, tacky interface 906b promotes electrical connectivity between the damaged SCE and the foreign object 905. In example 900, forming conditions for a discharge event (e.g., arch and / or spark) is initiated at SCE 901 to be terminated at the SCCE surface 902a. The discharge can deliver peak current density at the SCCE interface (e.g., the constraint surface 902a) that is electrically coupled with the counter electrode terminal tab that is electrically coupled with the counter-electrodes of the cell assembly. SEC 901 is separated from SCCE 902a by a gap including an insulating material that is part of the enclosure 903, e.g., external pouch that is electrically insulating. Example 920 corresponds to a condition in which the foreign object penetrates the sealed pouch but has not yet reached the internal cell assembly. The point of contact for the foreign object 905 to contact the SCCE 902a is illustrated by point 921. At the contact point 921 , the discharge (e.g., arc) occurs externally to the cell assembly, and internally to the enclosure. The discharge occurs through the shield structure without involving the active materials or the cell assembly. This spatial relocation of the discharge reduces thermal coupling with the active material of the cell assembly, and mitigates runaway propagation risk. In example 920, the foreign object 905 progresses through the sealed pouch 903 and completes the electrical connection of the shields prior to reaching the cell assembly. Energy dissipation occurs in proximity to the SCCE and remains spatially offset from the active electrochemical zone of the cell assembly. Example 940 corresponds to the condition in which the foreign object reaches the mid-plane of the cell assembly. A discharge contact point 941depicts the point of contact between the foreign object 905 and electrodes of the cell assembly, e.g., generating an electrical short. In the configuration illustrated in the example 940, the discharge occurs deeper within the cell stack. Such discharge is now moderated, since most of the current discharge occurred at location 921 outside of the cell assembly, as shown in example 920. The discharge remains moderate, e.g., due to the prior energy dissipation occurring along the shield path. The residual energy reaching the internal region may now be insufficient to trigger thermal runaway reaction to generate the harm. Such configuration of the staged shielding architecture can limit thermal excitation even when the discharge occurs at an internal location relative to the enclosure. Example 960 corresponds to the condition in which the foreign object enters the electrochemical cell directly, without passing through any structure that will allow such discharge to occur outside of the cell assembly-. In example 960, the foreign object penetrates directly into the electrode body of the cell assembly without prior contact with any shielding electrode pair. In such a case, the discharge 961 is internal to the cell assembly, and is more likely to cause a harmful reaction. Thermal runaway is caused due to the absence of arc mitigation structures.

[0141] In some embodiments, a shield configuration is positioned to protect a cell assembly. A shielding electrode pair is positioned in the pathway of a projected foreign object destined to enter from the ambient environment into a cell assembly. The shielding electrode pair are each electrically coupled with an opposing terminal tab of the cell assembly, e.g., thus carrying each of their charge. The shield configuration may protect the cell assembly from an electrically conductive foreign object. The shield configuration may define a conductive path external to the cell electrolyte. The shield configuration may define a spatial interface for energetic discharge event (e.g., arch and / or spark) external to the cell assembly. The shield configuration may redirect harmful energy away from internal electrode interfaces of the cell assembly. The foreign object may comprise an electrically non-conductive or an electrically conductive body (e.g., a nail). The foreign object may facilitate (e.g., create and / or cause) the discharge event between a shield-coupled electrode (SCE) and a shield-coupled counterelectrode (SCCE). The discharge may form prior to physical entry of the foreign object into the cell assembly. The shield configuration may spatially localize the harmful discharge event and / or prevent thermal propagation into the internal structure of the cell assembly.

[0142] In some embodiments, the discharge event external to the cell assembly may be sufficiently energetic to cause heat that will (indirectly) cause sufficient heat to trigger a thermal runaway reaction in the cell assembly. A large mass of SCE and / or SCCE may facilitate attenuation of the discharge intensity, e.g., at a time. Such attenuation may be important, e.g., when the velocity of penetration of the foreign object towards the cell assembly cannot be controlled such as slowed.

[0143] In some embodiments, an electrically conductive foreign object encounters a shield- coupled electrode (SCE) electrically connected with a terminal tab of a cell assembly. The foreign object, when electrically conductive, may acquire the charge of the electrode upon electrical contact with the SCE. The contact may occur through a terminal tab connection and / or through a conductive region of the SCE, e.g., a mass, a layered structure, a sheet (e.g., foil), tape segment, or any combination thereof. The larger the mass of the SCE, the more spread out the electric energy is within the SCE. The better the electrical coupling between the SCE and the foreign object will be, the more effective the discharge will be when reaching the SCCE. The charge acquired by the foreign object may be reduced as the SCE mass increases, e.g., attenuating the intensity of the discharge event. The distributed energy profile may attenuate the charge available for transfer during discharge. The ability to regulate intensity of the discharge at the point of discharge through passive adjustment of shield mass, may enable modulation of the discharge intensity, e.g., without reliance on active control such as active circuitry.

[0144] In some embodiments, the shield-coupled electrode (SCE) carries sufficient mass to modulate charge distribution upon foreign object induced discharge. The energy carried by (e.g., acquired by) the object, may vary based at least in part on the mass of the SCE, the electrical connectivity between the foreign object and the SEC, the electrical compatibility between the foreign object and the SEC, or any combination thereof. A higher mass of SCE may result in lower charge accumulation on the object, lower energy to be discharged by the discharge, and / or attenuated degree of harm caused by the discharge. The reduction in acquired charge may attenuate the discharge event at or, close to, the shield-coupled counterelectrode (SCCE). Passive mass tuning of the SCE may enable current-limiting behavior upstream of critical electrolyte exposure.

[0145] In some embodiments, the SCE is in electrical contact with a penetrating foreign object. The contact may convey electrical energy to the object (e.g., electrical potential). The SCE may be generated as a layered and / or wrapped structure. The wrapped structure may be about the cell assembly. The SCE may comprise at least one layer and / or wrap cycle. The layers may be formed by lamination, folding (e.g., Z folding), and / or roll-based fabrication. The SCE structure may be constructed layer-wise, e.g., to maintain surface engagement. The contact with the foreign object may enable (e.g., early and / or efficient) energy transfer, e.g., before the foreign object reaches the cell assembly. The layered interface of the SCE may reduce interfacial resistance and / or promote efficient current loading of the foreign object. The interfacial resistance may pertain to the resistance of electrical flow between the SCE and the foreign object. The interfacial resistance may pertain to lowering the friction between the foreign object and the SCE as it penetrates through the SCE towards the cell assembly. In some embodiments, the SCE comprises a mass of a tacky conduct interface, e.g., one ormore layers of a tacky conductor. The tacky conductor may enhance electrical contact between the SCE and the foreign object (e.g., nail). The electrical contact may occur during object penetration through the SCE. The tacky material may comprise carbon tape and / or adhesive-coated sheet, e.g., foil. The tacky material may deform locally under pressure. The deformation may maintain continuity of electrical connection. The tacky layer may improve charge transfer efficiency and / or reduce arcing variability during entry into the SCE. In some embodiments, the SCE material is selected for enhanced electrical compatibility between the tacky material and the SCE. The tacky material may comprise a conductive material disposed in a tacky material, e.g., a metallic powder disposed in a polymer or a resin. The tacky material can comprise (e.g., substantially) the same material type as the SCE, e.g., as an additive. The additive may comprise particulates or wires. The additive may be disorganized in the tacky material, or may be organized, e.g., aligned and / or weaved. The tacky material may comprise a polymer or a resin. The tacky material may comprise a material that is not electrically conductive. The tacky material may comprise a composite material. The polymer may be electrically conductive. The tacky material may comprise a conductive material of a different type from the material type included in the SCE. In some embodiments, the SCE material is selected for enhanced electrical compatibility between the conductive foreign object and the SCE. The SCE may be of (e.g., substantially) the same material type as the foreign object. The SCE may be of a different material type than the foreign object. The metals having good (e.g., superior) electrical compatibility may comprise silver, coper, gold, aluminum, or any combination thereof. Good electrically compatible pairs may comprise copper and silver, copper and gold, copper and aluminum, or gold and silver. In some embodiments, the SCE comprises copper, e.g., as at least a portion of the SCE such as a layer of the SCE.

[0146] In some embodiments, the electrical conductance of the SCE influences the behavior of the foreign object. The conductivity of the SCE may be (e.g., directly) proportional to the energy transfer between the SCE and the foreign object. A higher electrical conductivity of the SCE may promote more effective energy transfer between the SCE and the foreign object, between the SCE of the tacky material, and / or between the SCE and the SCCE. The foreign object may carry a charge based at least in part on its proximity or physical contact, with the SCE. A mutual electrical conductivity between the SCE and the foreign object may influence the intensity and / or efficiency, of the energy discharge surge. The surge may be exhibited as an electric arc when the foreign object reaches the SCCE. A higher-conductivity pairing may produce a more defined arc, enable earlier energy discharge and / or enable more efficient energy discharge. A good electrical conductor for SCE may comprise copper, silver, gold, aluminum, brass, bronze, and / or nickel. Some metals may be more resistive (e.g., stainless steel) than others (e.g., copper) to electrical conductance. The material selection of the SCE and / or SCCE may influence the discharge and / or arc formation. The material of the SCE,foreign object, tacky interface, and / or SCCE, may effect (e.g., reduce) variability in the discharge location outside the cell. The active material nature, electrolytic mixture, active material loading, and / or architecture of the cell assembly, may influence the degree of harm caused in the cell assembly that is generated by a discharge between the SCE and SCCE, and that is generated by a discharge internal to the cell assembly. Some active materials and / or electrolytic mixtures, are more susceptible to thermal runaway reaction, e.g., depending on their chemical makeup, diffusion coefficients, and heat distribution coefficients. Some cell architectures are more susceptible to thermal runaway reaction, e.g., depending on their heat distribution coefficients, e.g., see fig. 7. Some device settings are more susceptible to thermal runaway reaction, e.g., depending on ambient temperature, ambient pressure, flow of air, relative placement to heat sources, or any combination thereof. When engineering the construct, the above considerations influencing the harm (e.g., due to thermal runaway) can be considered.

[0147] In some embodiments, the shield comprises a mass sufficient to allow electrical energy transfer to a foreign object. A larger mass may be provided through (i) a thicker shield layer, (ii) multiple layering of shield material, (iii) multiple wrapping of the shield material, and / or (iv) any combination thereof. The shield material may be applied as a sheet (e.g., foil), mesh, and / or strip (e.g., aluminum wrap). The added mass may increase the total charge capacity of and / or its distribution in the shield. The shield may include the SCE and / or the SCCE. A higher charge accumulation capacity and / or higher charge distribution capacity, may reduce the residual energy carried by the foreign object. The mass configuration may delay arc onset, discharge onset, and / or suppress runaway initiation inside the cell assembly.

[0148] In some embodiments, the foreign object continues to plunge through after charging at the SCE, and / or after carrying the charged tacky interface. In some instances, the foreign object reached the SCCE. An energy surge may occur between (A) the foreign object and / or tacky interface and (B) the SCCE. The surge may be generated through a direct discharge, or through an indirect discharge (e.g., an electric arc and / or spark). The discharge may depend at least in part on one or more electrical parameters. The parameters may comprise (i) the amount of electrical energy carried by the foreign object, (ii) the charge stored in the shield (e.g., SCE and / or SCCE), (iii) the electrical connection between the shield and the foreign object, (iv) the electrical conductance between the foreign object and the shield, (v) the amount of electrical energy carried by any tacky interface, (vi) the electrical connection between any tacky interface and the foreign object, (vii) the electrical connection between the shield and any tacky interface, and / or (v) any combination thereof. The tacky interface may or may not be included in the shield. The discharge of energy between the SCE and the SCCE may release heat into the surrounding region. The heat may occur outside of, at, or inside of, the enclosure. The heat may occur near a face of the enclosure. The face may be an inner faceof the enclosure and / or an outer face of the enclosure. In some embodiments, the released energy may remain below a thermal threshold for a harmful thermal runaway reaction. The thermal threshold may prevent heat-induced runaway reaction in the cell assembly (e.g., from indirect thermal stimulation). The condition-dependent discharge may enable localized energy dissipation and / or suppress propagation events internal to the cell assembly.

[0149] In some embodiments, the energy surge is generated between a charged foreign object and the SCCE. The surge may produce a discharge. The discharge may be direct or indirect. The direct discharge may occur when the foreign object physically contacts the SCCE and / or when the SCE physically contacts the SCCE. The indirect discharge may occur when the foreign object does not physically contact the SCCE and / or when the SCE does not physically contact the SCCE. In the case of indirect physical contact, the discharge may be through an electric arc, spark, and / or heat (e.g., momentary discharge flash). The foreign object may carry an electrical polarity acquired from the SCE. The SCCE may present an opposing polarity aligned with the counter-electrode terminal tab, which is aligned with the counter electrodes of the cell assembly. The discharge may occur when the object reaches the SCCE discharge zone’s threshold distance. The energy surge may occur at a location physically outside the (e.g., sealed) cell assembly. The heat release may remain localized to the external region (e.g., outer wrap and / or laminate). The external location of the discharge (e.g., spark) may reduce direct exposure of the internal electrodes of the cell assembly to the discharge. In some examples, the discharge is not likely to initiate thermal runaway within the cell assembly if sufficient energy is discharged externally to the cell assembly and / or the thermal load remains below propagation threshold. The relocation of the initial surge path away from the active material of the cell assembly, may provide a non-invasive buffer architecture that absorbs risk without modifying internal cell chemistry and / or architecture.

[0150] In some embodiments, the foreign object penetrates SCCE during a motion. The motion may be continuous or non-continuous. The SCCE may comprise an external constraint layer (e.g., steel shell and / or rigid frame). The SCCE may comprise one or more layers. The SCCE may comprise a coating, e.g., an insulating coating. The SCCE may comprise a conductive core. The SCCE may or may not have a structure similar to the SCE. The SCCE and SCE may have one material type in common. The SCCE and SCE may have one material type that is different. The SCCE and SCE may have a similar architecture. The SCCE and SCE may have a different architectures. In an example, the SCE is a wound structure while the SCCE is a constraint system such as disclosed herein. Post penetration, the foreign object may reach the internal cell assembly. A direct short (e.g., an uncontrolled current flow) may occur between the internal electrodes upon penetration of the foreign object into the cell assembly. The short may involve the cathode, the anode, and / or the charge carrier medium. The foreign object may carry less residual energy (e.g., electrical charge) due to priordischarge between the SCE and / or the SCCE. The electrical impact of the foreign object’s penetration into the cell assembly, on the cell assembly, may be lower than the impact of the initial surge. The prior energy release between the SCE and SCCE may reduce the remaining energy carried by the foreign object to the cell assembly. The staged dissipation pathway may reduce the harm’s severity caused by the short. The mitigating effect of the shield pair may delay and / or decouple discharge (e.g., arc propagation) into the electrochemical layers of the cell assembly.

[0151] In some embodiments, the foreign object establishes a conduction event between the pair of shields (SCE and SCCE). The event may occur before the foreign object reaches the cell assembly. The conduction may constitute an external electrical fault. The foreign object may carry reduced residual charge after this interaction. The reduction in charge may result from arc discharge, spark, and / or direct current flow, outside the cell. The electrical energy may be dissipated through the shield pair. The diminished charge may reduce harm, e.g., at least in part by reducing internal heating of the cell assembly (e.g., local internal heating). The energy-limiting interaction may reduce a chance (e.g., measurably, substantially, and / or effectively prevent) thermal runaway within the cell assembly.

[0152] In some embodiments, the construct comprises a layered assembly of protective and / or electrochemical components. The construct may be also referred to herein as the “cell construct.” The components of the construct may comprise (i) a cell assembly, (ii) electrolytic mixture, (iii) enclosure, (iv) constraint system, (v) shield-coupled electrodes (SCE), (vi) a shield-coupled counter-electrode (SCCE), and / or (vi) a shield separator. The shield separator can comprise the enclosure. The shield separator may comprise an insulator of the constraint system. The SCE may comprise the constraint system, e.g., rigid body thereof. The cell assembly may comprise one or more-unit cells, e.g., enclosed in a sealed enclosure. The enclosure may be flexible (e.g., a pouch) or rigid (e.g., a can). The cell assembly may include terminal tabs comprising an electrode terminal tab and a counter-electrode terminal tab. The terminal tabs may extend from the cell assembly in the enclosure to an ambient environment external to the enclosure. The shield may be positioned externally to the cell assembly, e.g., in of the enclosure interior, at the enclosure body, at the enclosure seal, and / or outside of the enclosure body. The shield may include the SCE and / or the SCCE. The shield may be configured to intercept a foreign object before it reaches the cell assembly. The SCE may be configured to intercept a foreign object before it reaches the SCCE and before it reaches the cell assembly. The initial contact between the foreign object and / or the shield component(s) may enable transfer of electric charge. The contact may occur while the electrodes of the cell assembly remain isolated from the ambient environment. The timing and / or location of the encounter may influence (e.g., and control) the position of energy release. The configuration may preempt internal conduction events and / or prevent uncontrolled entry into theelectrochemical core. At least one SCE may be layered on, placed on, and / or wrapped around, the cell. The wrapping may be about (i) a stacking axis of the cell assembly, (ii) a perpendicular axis to the stacking axis, and / or (iii) another wrapping axis. The shield (e.g., SCE) may be coupled with its respective terminal tab, e.g., electrode terminal tab. The shield (e.g., SCE) may be external to the enclosure. The shield may be made of conductive material (e.g., aluminum or copper). The shield (e.g., SCCE) may be coupled with its respective terminal tab, e.g., counter-electrode terminal tab. The shield (e.g., SCCE) may be internal and / or external to the enclosure. The SCCE may contact at least one outer face of the cell assembly. The SCCE may form at least a section of a constraint system. The SCCE may comprise the constraint system. A shield separator may electrically isolate the SCE from the SCCE. The shield separator may comprise a polymer, resin, and / or composite material. The shield separator may include or exclude porosity, e.g., depending on their relative position with the enclosure. The shield separator and the cell assembly separator may have at least one material type in common. The shield separator may include at least one material type that is different from that of the cell assembly separator. The shield separator and the cell assembly separator may have at least one architectural feature that is of the same type. The shield separator may include at least one architectural feature that is different from that of the cell assembly separator. The architectural feature may comprise layer structure, bulk structure, wrapping structure, or any combination thereof. The shield may comprise a tacky interface. The shield separator may or may not include the material type of the separator disposed between the electrode and the counter electrode in the cell assembly. The cell assembly separator may comprise porosity, and the shield separator may be devoid of porosity. The cell assembly separator may be layered, and the shield separator may be non-layered. The cell assembly separator may comprise a plastic type, and the shield separator may comprise a lacquer type. A layer of the separator may be disposed within the enclosure (e.g., pouch) and / or laminate, or be laminated with, the shield layers. The shield-enclosure structure may promote passage of a foreign object though the shield-pair before contacting the cell assembly. The shield-enclosure structure may provide a directional path for fault energy and / or reduce the probability of the harm such as due to an internal thermal runaway reaction in the cell assembly.

[0153] In some embodiments, the cell assembly comprises unit cell(s) enclosed in a sealed housing. The housing may comprise a pouch. The housing may comprise layers, e.g., films. The enclosure (e.g., pouch) may allow traversal of an electrode terminal tab and a counterelectrode terminal tab therethrough, e.g., through its seal. The terminal tabs may extend outside the housing to enable external electrical connection. The terminal tabs may be mechanically joined and / or electrically coupled with external structures, e.g., power source and / or target device such as an electronic device that utilizes the electricity of the cellassembly for its intended functionality. The sealed housing may isolate at least the cell assembly and its electrolyte mixture, from the ambient environment such as from reactive species in the ambient environment. The configuration may support compact form factors (e.g., stacked laminate) and / or limit gas exchange between an interior environment of the enclosure and the ambient environment, e.g., during normal and / or faulted operation. Design of the terminal-tab may provide a fixed electrical polarity to shield-coupled elements, e.g., the SCE and / or SCCE. The terminal-tab may enable directional energy redirection, e.g., during fault conditions.

[0154] In some embodiments, at least one shield (e.g., SCE coupled with the cathode) of a pair of shields is placed relative to the cell assembly. The placement may be such that a foreign object traveling in a fault trajectory will encounter the shield pair before reaching the cell. The at least one shield component may be positioned on the surface of the cell assumedly, e.g., the constraint system acting as a SCCE. The shield may comprise a layered structure, e.g., contacting the enclosure and / or integrated within a laminate, e.g., that is electrically insulating. The shield may form a pocketed electrode, the pocket of which is electrically insulating. The pocket and / or laminate, may comprise the shield separator. The shield (e.g., SCE) may be wrapped about at least a portion of the outer perimeter of the cell assembly, e.g., form a foil band around a prismatic pouch enclosure. The placement of the shield may be with respect to an expected direction of mechanical intrusion of the foreign object. The expected location may be at least in part defined by a cavity in the target device in which the construct (including the cell assembly) is designed for placement such as for insertion. The location of first contact of the foreign object with the construct, may determine when the foreign object acquires polarity. The placement, wrapping and / or layering arrangement of the shield, may trigger external discharge on approaching, or on contacting, an oppositely charged body such as an oppositely charged shield. The configuration of the shield pair may interrupt energetic (e.g., electrical and / or heat) discharge into the active region.

[0155] In some embodiments, at least one SCE (e.g., the cathode) of the SCEs pair wraps around an axis and / or around the cell assembly. The wrapping may follow the geometric layout of the internal cell stack. The axis may be aligned with the stacking axis of the cell. The stacking axis may define the direction of electrode layering within the pouch. The axis may alternatively be normal to the stacking axis. The normal axis may correspond to a sidewrapping geometry along the outer edge of the assembly. The axis may also be a wrapping axis of the cell (e.g., in a jelly roll configuration). The SCE may follow a helical and / or circumferential path. The wrap may include a continuous spiral and / or segmented banding pattern. The SCE may provide conformal surface coverage and / or planar protection. The orientation may be chosen based on the likely direction of external force. The aligned wrapmay control the point of initial contact with a foreign object. The axis-specific configuration may govern arc location and / or restrict energy propagation into the electrochemical interior.

[0156] In some embodiments, the shield is arranged about a cell assembly. The shield (e.g., SCE and / or SCCE) and the cell assembly may have at least one material type in common. The shield may include at least one material type that is different from that of the cell assembly. The shield and the cell assembly may have at least one architectural feature that is of the same type. The shield may include at least one architectural feature that is different from that of the cell assembly. The architectural feature may comprise layer structure, wrapping structure, stacking direction, aspect ratio (e.g., surface aspect ratio), or any combination thereof. The similarities between the shield and the cell assembly, may streamline manufacturing processes of the construct.

[0157] In some embodiments, the shield (e.g., SCE) follows a structural arrangement similar to that of wrapped and / or stacked electrode arrangement. The shield may adopt a geometry comparable to, or reminiscent of, a wrapped electrode encircling the cell assembly. The wrap may extend over one or more sides (e.g., faces) of the enclosure, such as fully enclose the outer faces of the enclosure. The shield may adopt a stacked arrangement aligned, or misaligned, with the layering of the internal electrodes. The stacked layout may follow the same, or a different, planar direction as the cell assembly. The external geometry may be selected based at least in part on form factor constraints and / or expected direction of foreign object penetration path. The structural alignment may enable energetic release (e.g., polarity transfer and / or arc generation) at a predictable interface external to the cell assembly. The similarity to established electrode formats may support material compatibility and / or streamline integration into existing assembly processes.

[0158] In some embodiments, a shield is electrically coupled with an electrode terminal tab of the cell assembly. The terminal tab may correspond to the anode or the cathode terminals of the cell assembly. The electrical contact may be made at least in part by welding (e.g., spot welding), bonding (e.g., pressure bonding), and / or lamination. The bonding may comprise coupling with a conductive liquid and / or tacky material such as disclosed herein. The shield may be inside the cell housing or external to the housing (also referred to herein as “enclosure”). An internal placement of at least one component of the shield (e.g., SCCE) may allow compact integration with the cell assembly, e.g., comprising stacked and / or folded cells. An external placement to the enclosure may facilitate mechanical access and / or heat dissipation, e.g., when placed on the enclosure’s exterior and / or further away from the cell assembly. The tab-to-shield coupling may provide a consistent polarity transfer path and / or define a fixed electrical boundary for the outer shield.

[0159] In some embodiments, the shield comprises a conductive material type compatible with the cell’s current collector. The material may include an elemental metal, a metal alloy,tacky interface, any plurality of types thereof, or any combination thereof. The material may be any shield and current collector material such as disclosed herein. The shield may be fabricated as a sheet (e.g., foil), mesh, layered structure, and / or composite laminate (e.g., aluminum foil backed with a tacky interface). The shield may comprise at least two different material types, e.g., at least two elemental metal, an elemental metal and a conductive tacky interface, and / or an elemental metal and a metal alloy. The conductivity of the material may influence current path stability between at least one shield of the pair of shields and the foreign object, and / or between the shields of the pair of shields. The mechanical hardness of the shield material may affect puncture resistance and / or deformation during penetration of the foreign object. One shield component (e.g., SCE) may be placed adjacent to the other shield component (e.g., SCCE). The SCE may be spatially away from the cell assembly than the SCCE. The relative placement of each shield component to the cell assembly, may follow a sequence of outer SCE, intermediate SCCE, and internal cell assembly. The physical ordering may be designed to direct energetic discharge away from the cell assembly and / or distribute discharge energy across the shield pair.

[0160] In some embodiments, the SCCE is located between the SCE and the cell assembly. The SCCE may function as a mechanical constraint, a thermal sink, and / or a conductive absorber. The SCE may be placed, layered, and / or be wrapped around an outer surface of the enclosure, e.g., that encloses the SCCE and the cell assembly. The enclosure (e.g., pouch) may include multilayered films, e.g., comprising polyethylene-aluminum-polyester layer sequence. The enclosure may contain electrolyte, cell assembly, and / or the SCCE, e.g., in a pocketed such as in a laminated structure, e.g., the first electrode type that a foreign object encounter as it travels towards the cell assembly. The SCE may form the outermost conductive surface. The relative arrangement of the construct’s components (e.g., layering) may create a gradient of electrical potential from an exterior of the construct to interior of the construct. The inward sequence may delay thermal propagation and / or reduce the likelihood of fault penetration into the active region of the cell assembly. In case the SCCE is pocketed (e.g., along with the cell assembly), the pocket may serve as a shield separator from the SCE. The SCE may be disposed in the enclosure, at the enclosure body, or outside of the enclosure. In some embodiments, the SCE is located outside of the enclosure.

[0161] In some embodiments, a shield-coupled counter-electrode (SCCE) couples with the counter-electrode terminal tab of the cell assembly. The terminal tab may correspond to the anode and / or cathode. In some embodiments, the terminal tab to which the SCCE is coupled with, is the anode terminal tab of the cell assembly. The electrical connection may be formed through any coupling methodology disclosed herein, e.g., between the shield and the terminal tab such as including direct welding and / or laminated contact. The SCCE may establish a second polarity region outside the electrochemical core. The SCCE may serve as the terminal-specific boundary for discharge (e.g., arc generation. The polarity assignment may complement the electrical role of the outer SCE, e.g., by opposing it. The paired polarities may enable directional charge transfer and / or external surge containment between the shield pair.

[0162] In some embodiments, the SCCE is positioned outside the pouch and / or inside the sealed housing (e.g., a rigid can). A shield separator may contact the SCCE, e.g., as a pocket (e.g., laminate), and / or as a deposited insulator (e.g., lacquer). A shield separator may contact the SCE, e.g., as a pocket (e.g., laminate), and / or as a deposited insulator (e.g., lacquer). External positioning of the shield pair may involve surface attachment (e.g., affixation) of one shield component through a shield separator. For example, the SCE has an insulating surface coating forming the shield separator, and the SCE, though the shield separator coating, contacts the SCCE. For example, the SCCE is pocketed in an insulator forming the shield separator, and the SCCE, though the shield separator pocket, contacts the SCCE. Any of the shield components may couple with the outermost surface of the enclosure, e.g., in keeping with their relative directional layered structure. Any of the construct components may be internally positioned in the enclosure. The internal positioning may include direct integration into the structural constraint system (e.g., compression plate). The location of the shield (e.g., SCCE) may be selected based at least in part on mechanical strength, heat conduction, and / or spatial availability. An internal placement of the shield in the enclosure may reduce movement under mechanical stress. An external placement of the shield may ease inspection. An external placement of the shield may improve heat dissipation and / or venting (e.g., due to gas generation), that may occur during fault discharge. The geometry may be aligned to maximize surface area facing the foreign object as it propagates along its path.

[0163] In some embodiments, the shield is formed from a conductive material. The conductive material may be similar to that used for current collectors. The material may comprise (i) an elemental metal, (ii) a metal alloy, (iii) a plurality thereof, or (iv) any combination thereof (e.g., nickel or copper-based alloys). The shield may contact at least one external face of the enclosure pouch. The contact may be continuous or edge-mounted. The shield (e.g., SCCE) may serve as both an electrical element and a constraint mechanism. A dual-role shield may function as a discharge-facing terminal and / or reinforce the cell assembly against intrusion. The integration of structural and / or electrical function of the shield, may support safety during impact-driven events. The integration of structural and / or electrical function, may support mechanical integrity during impact-driven events.

[0164] In some embodiments, a shield separator is placed between the SCE and the SCCE. The separator may electrically isolate the shield electrode from the shield counter electrode. The separator may electrically isolate the outer shield electrode from the inner shield counter electrode. The separator may comprise a polymer, a resin, and / or any combination thereof. The separator may comprise a separator and / or insulator, material such as disclosed herein.The insulating composition may resist electrical and / or thermal degradation. The separator may be formed as a composite laminate (e.g., polyester bonded with polyethylene). The material properties may remain stable under compression and / or surface contact. The electrical barrier may attenuate (e.g., measurably and / or substantially prevent) premature discharge. The electrical barrier may reduce uncontrolled electrical cross-conduction between shield layers.

[0165] In some embodiments, the shield separator is porous. In some embodiments, the shield separator is (e.g., substantially and / or measurably) devoid of pores. A porous separator may resemble a microporous separator used the cell assembly. A non-porous variant of a shield separator may serve as a barrier for reactive species, e.g., may serve as a liquid and / or gas barrier. The porosity may influence electrical breakdown behavior and / or venting performance. A porous separator may enable passive, electrolyte passage, charge carrier passage, and / or thermal venting (e.g., gas diffusion through tortuous pores). A porous shield separator may be beneficial if the shield separator is disposed in the enclosure, e.g., if at least one of the shield pair is disposed in the enclosure. A non-porous separator may enhance dielectric strength across stacked shields. A non-porous shield separator may be beneficial if the shield separator is disposed outside of the enclosure, e.g., when at least one shield of the shield pair is disposed externally to the enclosure. The selected shield separator structure may contrast with the internal separator used between anode and / or cathode inside the cell. When any component of the shield system is disposed in the enclosure, that component should be configured to be compatible with the electrochemistry of the electrochemical cell assembly, e.g., during the prescribed use of the device and / or in the prescribed conditions of the device - such as disclosed herein.

[0166] In some embodiments, the enclosure (e.g., pouch) incorporates the shield separator into its body, e.g., its laminate structure. The separator may be embedded between film layers of the enclosure. The enclosure layers (e.g., laminate) may contain a metallic foil, a polymer insulator, and / or a resin-adhesive interface. The separator may serve as a laminator for the SCE and / or the SCCE, e.g., forming a pocketed shield electrode. The shield separator may provide a bond-line for external wrap adhesion (e.g., during roll wrapping such as including lamination). The lamination may retain alignment under thermal and / or mechanical stress. The integrated design may stabilize the shield stack and / or minimize structural drift during deformation, the shield stack comprising the SCE, shield separator, and SCCE. In some embodiments, the construct comprises SCCE(s), shield separator(s), and SCE(s).

[0167] In some embodiments, methodologies disclosed herein provide a multi-layer shielding system designed to manage electrical surge events such as those promoted (e.g., caused) by foreign object penetration in an electrochemical cell. A penetrating object may acquire, or drag, electrical polarity through contact with a shield-coupled electrode (SCE) positioned externallyto the cell assembly. Dragging the electrical polarity may be facilitated by a conductive polar interface coupled with, or as part of, the SCE, being dragged by the foreign object as it approaches the SCCE. The foreign object may travel toward a shield-coupled counterelectrode (SCCE), where a polarity-driven discharge (e.g., arc and / or spark) may be generated. The energy surge may be released outside the cell assembly, e.g., and outside of the sealed housing. The external energetic release may limit thermal load exposure on the cell assembly. The shielding configuration may reduce the likelihood of thermally triggered failure within the cell assembly. The SCE may be disposed on and / or around the enclosure structure. The SCCE may be positioned closer to the cell assembly and / or may serve a dual role such as a constraint mechanism. An insulating shield separator may be disposed between the SCE and the SCCE. The separator may comprise a polymer, resin, and / or composite material. The separator may comprise any insulator and / or separator material such as disclosed herein. The separator may or may not be porous, e.g., depending on structural and / or electrochemical requirements. The separator may be integrated into the enclosure wall and / or embedded as a laminate layer. The physical arrangement of the SCE, SCCE, and shield separator may enable energy dissipation in a spatially controlled sequence. The physical arrangement may hinder (e.g., prevent) uncontrolled electrical propagation into the cell assembly.

[0168] In an example, a pouch-based lithium-ion cell was assembled using a cathode comprising lithium cobalt oxide (LCO) coated onto an aluminum current collector. The anode comprised a silicon-based active material coated onto a copper current collector. The electrodes were stacked and enclosed in a sealed pouch comprising a laminate of polyethylene and aluminum. A stainless-steel constraint (SS301) coated with ClearClad was coupled with the anode terminal tab and positioned to mechanically support the interior cell layers.

[0169] In an example, an aluminum wrap was applied around the outer surface of the sealed pouch. The wrap was electrically coupled with the cathode terminal tab. A copper film was placed over the aluminum wrap. A carbon tape layer was applied over the copper film. The copper-carbon laminate formed a contact-enhancing outer structure. The outer structure served as the SCE. The configuration allowed a penetrating object to sequentially contact each outer conductive layer before reaching the internal electrodes.

[0170] In an example, a stainless-steel nail was driven through the copper film, the carbon tape, and the aluminum wrap. The nail then passed through the pouch wall and reached the stainless-steel constraint. The aluminum wrap acquired cathodic potential through its connection to the cathode tab. The constraint held anodic potential through its connection to the anode tab. The penetrating object followed a defined electrical gradient through external shield layers before entering the cell interior.

[0171] In an example, the mass of the aluminum wrap was varied to evaluate arc behavior and thermal performance. Wrap lengths of 55 cm and 65 cm were tested and resulted in thermal runaway. The maximum temperature in both cases exceeded 400°C. Wrap lengths of 70 cm, 75 cm, and 80 cm were also tested. No thermal runaway occurred in those tests. The maximum recorded temperatures were 104°C, 98°C, and 84°C, respectively. The test series demonstrated that increased aluminum mass suppressed ignition and reduced peak temperature during foreign object penetration.

[0172] In an example, the shield-coupled electrode (SCE) and the shield-coupled counterelectrode (SCCE) were electrically coupled with opposite terminals of the cell. The SCE was electrically connected with the cathode terminal tab. The SCCE was electrically connected with the anode terminal tab. The terminal assignment defined opposing polarities for the shield layers. A foreign object passing through the outer conductive wrap acquired cathodic potential. When the object reached the SCCE, an arc was generated due to the polarity difference. The arc occurred outside the electrolyte-filled region of the pouch.

[0173] In an example, the arc formed during nail penetration was visible between the carbon- coated outer wrap and the stainless steel SS-301 constraint. The visible discharge occurred prior to pouch breach. The spark location remained external to the internal electrodes. The released energy was absorbed by the external conductive layers. The constraint structure remained mechanically intact during the arc event. The observed energy release was short in duration and did not initiate combustion within the cell.

[0174] In an example, the constraint layer was mechanically fixed within the pouch. The constraint remained coupled with the anode terminal tab throughout cell operation and testing. The constraint structure supported the internal stack and functioned as an electrical endpoint for fault current. The use of a metallic constraint layer allowed for direct energy absorption during discharge events. The structural role and electrical role of the constraint were combined in a single element.

[0175] In an example, the copper film and carbon tape layers over the aluminum wrap enhanced surface contact between the foreign object and the outer shield. The carbon tape provided a compliant and conductive interface. The compliant interface allowed the nail to deform and maintain contact during entry. The enhanced contact improved arc consistency and reduced variability across repeated penetration tests. The copper-carbon structure formed a hybrid wrap functioning as the outermost shield interface.

[0176] In an example, the test structure was prepared without changing electrolyte composition or active material formulation. The only variable across tests was the aluminum wrap length. The results demonstrated that passive arc suppression can be achieved using changes to external conductive structure alone. The system suppressed thermal runaway bymanaging fault discharge outside the electrolyte zone. The shield configuration enabled passive protection without active switching or electronic control.

[0177] In some embodiments, a construct comprises a shield pair, e.g., a shield-coupled electrode (SCE) and a shield-coupled counter-electrode (SCCE). The shield (e.g., SCE) may include a stack comprising copper foil, carbon tape, and / or an aluminum wrap. A sealed pouch may enclose the cell assembly and the SCCE. A foreign object may enter the construct along a vertical intrusion path. The foreign object may first contact the SCE. A discharge (e.g., arc and / or spark) may form between the SCE and the SCCE as the foreign object approaches the SCCE. The discharge location may vary based at least in part on the penetration depth of the foreign object, the charge it carries, and / or its velocity. The sealed enclosure (e.g., pouch) may electrically isolate the electrodes and / or suppress direct exposure of the electrolyte to the ambient environment. The discharge may occur prior to contact, e.g., as an arc discharge. A penetration beyond the SCCE may result in localized heating and / or internal disruption of cell assembly. The absence of an external shield pair to the cell assembly, may increase the probability of thermal runaway in the cell assembly. The spatial arrangement of the SCE, the SCCE, and the shield separator relative to the cell assembly, may enable passive control of harmful discharge without requiring (e.g., active such as controlled) protective circuitry.

[0178] In some embodiments, the shield (e.g., SCE) is realized using a range of physical formats. The SCE may comprise (i) a planar sheet (e.g., foil), (ii) a multilayer laminate, (iii) a volumetric block, and / or (iv) a conformal wrap. A planar foil may provide uniform current distribution across planar (e.g., flat) surfaces. A multilayer laminate may enhance mechanical compliance and / or provide a tacky interface. A volumetric block may absorb higher charge density across its thickness and / or may server as a physical blockage to penetration of the foreign object into the cel assembly. A (e.g., conformal) wrap may provide surface-following protection with minimal edge discontinuities. The conductor material may comprise aluminum, copper, nickel, gold, silver, platinum, a metal alloy such as stainless steel, any plurality of types thereof, any mixtures thereof, any composites thereof, or any combination thereof. The conductor may be any conductor disclosed herein. The choice of material may affect conductivity, corrosion resistance, charge transmission, charge carried by the foreign object, and / or deformation behavior, during impact. The surface treatment of the shield (e.g., SCE) may comprise (i) an untreated finish, (ii) a tacky coating, (iii) a conductive film, and / or (iv) a micro-patterned structure. A tacky interface coating may increase contact fidelity under dynamic loading. A conductive film may improve current injection efficiency during discharge, e.g., arc closure. A micro- patterned surface may reduce contact resistance and / or localize current distribution. The placement geometry of the shield (e.g., SCE) may include (i) a topfacing sheet, (ii) a wrap, (iii) a (e.g., full) surface laminate, and / or (iv) an edge-aligned, configuration. The wrap may be along four consecutive faces of the cell assembly, e.g.,disposed in a prismatic enclosure. The wrap may comprise a cylindrical or a helical wrap. A cylindrical wrap may encircle the wrap non-helically along a curved surface of a cylinder. A spiral wrap may encircle the pouch helically. A full-surface laminate may provide broad coverage with embedded insulation. An edge-aligned structure may concentrate the harmful discharge along predefined containment zones. The mounting approach may comprise (i) mechanical fixation, (ii) lamination, (iii) adhesive bonding, and / or (iv) passive coupling, e.g., using heat and / or pressure. Mechanical fixation may include tabs or riveted joints. Lamination may embed the shield in a pocket or in an enclosure (e.g., pouch) layer. Adhesive bonding may enable placement on curved and / or contoured surfaces. Passive pressure coupling may retain contact during thermal expansion, e.g., without rigid support. The electrical interface coupling may involve (i) welded attachment, (ii) pressure-based contact, (iii) conductive paste, (iv) flexible bus connectors, and / or (v) thermally induced coupling. Each shield implementation may be selected based at least in part on fault response speed, structural compatibility, and / or integration with existing manufacturing processes. The shield may comprise a (e.g., single) metallic layer a composite having a laminated interface (e.g., carbon tape over copper foil), any plurality thereof, or any combination thereof. A foreign object may contact the SCE before reaching the enclosure. The contact interface may absorb charge and / or initiate discharge. The discharge location may depend on geometry, material type, and / or surface pressure. The spatial arrangement of SCE and SCCE may define a tailored electrical response envelope. The physical design of the shield may passively control discharge location, discharge timing, and / or discharge energy distribution with respect to the cell assembly.

[0179] In some embodiments, the foreign object may penetrate from an interface of the cell assembly. The shield (e.g., SCE) may be disposed on at least one side of the cell assembly. At least one SCE may be provided along the expected penetration path. The counter shield (e.g., SCCE) may be positioned on at least one side of the cell assembly. At least one countershield may be provided along the expected penetration path of the foreign object. The relative positioning of each of the pair of shields may be adapted based at least in part on the geometry of the housing. The relative positioning of the pair of shields may be adapted based at least in part on the geometry and / or of the orientation, of the cell assembly.

[0180] Fig. 10 illustrates four examples of constructs, each incorporating a different construct configuration for protection against foreign object penetration towards the cell assembly. In example 1000, the construct includes an SCE 1001 positioned above, and contain a face of, a sealed enclosure (e.g., pouch) 1003. The enclosure 1003 encloses an electrochemical cell 1004 and the SCCE comprising constraint portions 1002a and 1002b coupling two plates such as endplate 1004 as part of a constraint system. The SCCE is electrically coupled with the electrode (e.g., anode) terminal tab - not shown. The SCCE is made from a conductive material (e.g., stainless steel). The SCE 1001 is electrically coupled with the counter electrode(e.g., cathode) terminal tab. In example 1000, the SCE is a layered structure of a conductive hard material interlaced with a tacky interface in a manner similar to SCE 901 of Fig. 9. In example 1020, the construct includes an SCE 1021 having a contact-enhancing layer 1022 composing a tacky interface, whereas the rest of the SCE layers 1021 include layers of hard material such as metal. The tacky interface 1022 may comprise carbon tape over copper foil or any other tacky interface material such as disclosed herein. The tacky material 1022 may improve contact consistency and / or charge transfer during impact. The contact interface may be between the foreign object and the SCE, between the foreign object and the SCCE such as though the foreign object being at least partially covered by the tacky material, and / or between the SCE and the SCCE such as through the tacky material dragged by the foreign object. In example 1040, the SCE 1041 is implemented as a volumetric mass (e.g., block) element. A tacky interface 1042 is positioned between the block and the ambient environment, being the first point of contact with the foreign object directed towards the cell assembly. The SCE 1041 may offer broader energy absorption, e.g., by being denser than the layered structure such as 1021 or 1001 , e.g., having more mass per volume. The tacky interface in each of the structure showed in example 10, is shown as an optional element. In example 1060, the SCE 1061 is shaped to conform with the outer surface of the sealed enclosure 1063 in a manner similar to example 1001 , while the cell assembly is a wrapped cell assembly rather than a stacked cell assembly. The shaped SCE 1061 defines a form-fitted conductive layer that maintains surface engagement along a predefined intrusion path, at a face of the cell assembly. In example 1060, the shield separator and the SCCE can be disposed in the enclosure (shield separator and SCCE not shown). Each example shown in Fig. 10 demonstrates a distinct implementation of SCE geometries aligned with anode-side SCCE positioning. The SCE form influences discharge generation, localization, and / or discharge containment outside the internal electrolyte. The tacky interface in each of the structure showed in example 10, is shown as an optional element

[0181] In some embodiments, a construct is designed to manage harmful discharge using shielded electrode pair arrangements. The construct may comprise (i) an electrochemical cell, (ii) a shield-coupled electrode (SCE), (iii) a shield-coupled counter-electrode (SCCE), (iv) a tacky interface layer, (v) a shield separator, and / or (vi) an optional outer enclosure. The enclosure may enclose the cell assembly and optionally the upper at least one of the pair of shields. The enclosure may or may not enclose the shield separator. The enclosure may comprise an insulator that may form the gap to isolate the SCE from the SCCE, or the SCCE from the cell assembly. In some embodiments, the cell assembly is covered by an insulator, e.g., a ceramic insulator such as an alumina. The insulator of the cell assembly may serve as the gap between the SCCE and the cell assembly. The SCE may have at least one fundamental-length-scale (FLS) different (e.g., shorter) from the internal cell assembly, e.g.,along (i) length, (ii) width, and / or (iii) wrap circumference. The different FLS may be larger or smaller. An additional conductive layer (e.g., of one material type) may be disposed above the other portion of the SCE (e.g., having another material type and / or tacky interface). The conductive layer may be electrically coupled with the other portion of the SCE. In an example, the conductive layer comprises copper coupled with tacky carbon to form a tape, and the other portion comprises wrapped or otherwise layered aluminum. The additional (e.g., and external) layer may have at least one FLS greater than the SCE and the electrochemical cell. In some configurations, the enclosure encloses the shield electrode pair and the cell assembly. In some configurations, the enclosure is devoid of the shield system (e.g., the shield electrode pair), while enclosing the cell assembly. The cell assembly may comprise any cell assembly architecture, e.g., stacked cell architecture. The cell assembly may comprise a wrapped (e.g., jelly roll) structure. The shielding pair (also herein “shielding system”) may include an electrically conductive mass, e.g., in the form of a slab. An outer insulating layer may be disposed over the mass, e.g., slab. The outer insulating layer may have a greater FLS than the cell assembly and the conductive mass. The structural arrangements may attenuate occurrence of a harmful discharge in the cell assembly and / or support discharge localization externally to the cell assembly during mechanical penetration of a foreign object. In some embodiments, the shielded cell assembly may be disposed within a housing that comprises (i) an insulating layer, (ii) a conductive metallic layer, (iii) a sealed structure. The sealed structure may comprise a laminate. The sealed structure may be gas and / or liquid tight.

[0182] Fig. 11 illustrates four structural configurations of a construct, each comprising a cell assembly, a shield-coupled electrode (SCE), a shield-coupled counter-electrode (SCCE), and a tacky interface. The examples show different positions and elements that can serve as shield separators, different cell assembly types, and different relative positions of SCE and SCCEs with the enclosure.

[0183] In example 1100, enclosure 1103 encloses the cell assembly 1101 , an SCCE 1102 - a constraint system, SCE including a layered structure 1105 (e.g., metal sheets) and tacky interface 1104. The SCE components are laminated into laminate 1103 comprising an insulator to form a pocketed electrode. The SCE can be electrically coupled with an electrode terminal of cell assembly 1101 (terminal not shown). The SCCE 1102 can be electrically coupled with the counter-electrode terminal of the cell assembly 1101 (terminal not shown). A gap 1106 is disposed between the pocketed SCE and the electrochemical cell 1101. The gap 1106 spatially isolates the upper shielding structure from the internal electrode mass. In other embodiments, the gap can be eliminated, e.g., since the SEC is pocketed in an insulating pocket 1103.

[0184] In example 1120, the enclosure 1123 encloses (i) cell assembly 1121 , (ii) SCCE 1122 - a constraint system, (iii) the tacky interface 1124, and (iv) the layered structure 1125, whichlayered structure 1125 and lacky interface 1124 together from the SCE. The SCE can be electrically connected with the electrode terminal of cell assembly 1121 (terminal not shown). The SCCE 1122 can be electrically connected with the counter-electrode terminal of cell assembly 1121 (terminal not shown). The FLS of the SCE is shorter than that of the cell assembly 1121. The configuration (e.g., example 1120) demonstrates a shield structure fully enclosed within the enclosure, with a minimized upper electrode envelope. In example 1120, the cell assembly and the SCCE are enclosure in a pocket 1123 such as a laminate, whereas the SCE is not enclosure in the pocket. When the pocket is formed of an insulating material, the pocket can serve as the shield separator.

[0185] In example 1140, the enclosure 1143 encloses (i) the cell assembly 1141 , (ii) the SCCE 1142 - constraint system, (iii) the tacky material 1144 of the SCE, (iv) and the non-tacky material SCE portion 1145, and (v) the shield separator1146 as a standalone layer. The SCE can be electrically coupled with the electrode terminal of the cell assembly (electrode terminal not shown). The SCCE can be electrically coupled with the counter-electrode terminal of the cell assembly (counter-electrode terminal not shown). The shield separator 1146 is positioned between the SCE and the SCCE to for the shield system, which is disposed in the enclosure along with the cell assembly. The FLS of the shield separator 1146 is greater than the SCE, greater than the opposing face of the SCCE, and greater than the opposing face of and the electrochemical cell 1141.

[0186] In example 1160, the shield system is disposed outside of the enclosure containing the cell assembly. The electrochemical cell 1161 comprises a wrapped structure, e.g., jelly roll type. A tacky material 1164 is disposed between the SCE 1165 and the ambient environment, making it the first encountered layer with a foreign object that progresses along a path similar to the one delineated in Fig. 9. The SCE includes layered structure 1165 and tacky material 1164. The SCE can be electrically connected with the electrode terminal tab of cell assembly 1161 (terminal not shown). A shield insulator layer 1163 is disposed between the SCE and SCCE 1163 that contacts, or can be a part of, enclosure 1166. A SCCE 1162 is in a form of a slab. SCCE 1162 can be electrically connected with the counter-electrode terminal tab of cell assembly 1161 (terminal not shown).. The shield insulator 1163 has an FLS greater than the SCE, than the SCCE, and electrochemical cell 1161. The configuration (e.g., example 1160) represents an external enclosure, or an enclosure-free, shield system, e.g., with mass-tuned shielding geometry.

[0187] In some embodiments, an electrochemical device comprises a housing comprising an aluminum sheet, e.g., foil. The housing may enclose a cell assembly such as a stacked electrode assembly. The electrode assembly may comprise unit cells arranged along a stacking axis. A cathode terminal tab may extend from the housing. The cathode terminal tab may comprise aluminum. A weld may join the cathode terminal tab to an external conductorserving as a shield, e.g., SEC. An anode terminal tab may extend from the housing of the cell assembly. The anode terminal tab may comprise nickel, copper, any plurality of types thereof, or any combination thereof. The terminal tabs may provide electrical connection to the respective electrode(s) of the cell assembly, e.g., depending on polarity.

[0188] Fig. 12 illustrates constructs as top view, cross sectional view, when the SCE is wrapped and is unwrapped. The construct 1200 comprises housing 1202, e.g., a pouch. The housing 1202 comprises a wrapped foil 1209 shown in its wrapped state. The wrapped foil may or may not include a tacky material. The housing 1202 encloses a cell assembly 1251. The cell assembly can comprise stacked unit cells. An electrode (e.g., cathode) terminal tab 1204 extends from housing 1202. The electrode terminal tab 1204 can comprise aluminum. A wrapped conductive sheet forms wrapping 1209 around enclosure 1202. A coupler (e.g., including a weld) 1210 connects the electrode terminal tab 1204 to an external conductor wrapping 1209 though tab 1206 that is part of the external conductor. In this way the external conductor that forms the SCE is coupled with the electrode terminal tab of the cell assembly disposed in housing 1202. A counter electrode (e.g., an anode) terminal tab 1208 extends from the housing 1202. The counter-electrode terminal tab 1208 can comprise nickel, and can be coupled with the constraint system (not shown) that serves as an SCCE. The terminal tabs 1204 and 1208 provide electrical access to the internal electrodes of the electrode assembly disposed in housing 1202. Example 1260 shows components of the construct shown in example 1200. The external conductor of example 1200 is shown as an unwrapped configuration including sheet 1264 having tab portion 1265, which is the tab portion 1206 in example 1200. Sheet 1264 is shown in example 1250 as wrapped about housing 1252 to form wrapping 1253, the wrapping being about cell assembly 1251 having stacked unit cells.

[0189] In some embodiments, structural penetration conditions of a foreign object into the construct are recorded, e.g., using front-side and back-side visual documentation. The shielding layers may comprise aluminum foil, copper foil, and / or carbon double-sided tape. The back side may show deformation and / or displacement of the layered structure after full penetration. The front side may show active entry of the foreign object during discharge. The combined documentation may confirm electrical path closure, energy dissipation zone, and / or structural displacement behavior, e.g., in response to mechanical intrusion. The construct may be any construct disclosed herein.

[0190] Fig. 13 shows photographic examples 1300 and 1350 of prismatic constructs. Example 1300 shows the back side of a cell assembly enclosed in an enclosure, after nail penetration. An aluminum foil 1302 is wrapped about a pouch hermetically sealing a cell assembly (cell assembly not shown), the wrapping being about four successive side surfaces of the prismatic pouch. A copper foil 1304 encircles an external surface of the aluminum foil 1302 - encircling the same four successive side surface of the prismatic pouch. The copper foil 1304 is coupledwith a carbon double-sided tape facing the aluminum foil, the carbon double sided tape including the tacky interface (not shown). A foreign object 1306 (e.g., metal nail) has penetrated through the layered structure and exited the back side of the prismatic pouch. The cell assembly is coupled with terminals 1308a and 1308b, the cell assembly being disposed in a sealed pouch, and the terminals extending to the ambient environment from the interior of the sealed pouch. The aluminum wrapping 1302 includes tap portion 1309 that is coupled with electrode terminal tab 1308b. Example 1350 shows the front side of the cell during nail penetration. The aluminum foil 1352 is disposed below a conductive tacky material 1354. A foreign object 1356 (e.g., a metal nail) is shown as entered the construct. The examples illustrate structural conditions after a nail penetration test was performed on a shielded construct, the shield construct not incurring any visible harm, e.g., such as due to a thermal runaway reaction.

[0191] In some embodiments, an SCE comprises a tacky interface. The tacky interface may comprise an adhesive layer comprising a conductive material such as disclosed herein, e.g., an allotrope of elemental carbon. The SCE may comprise two type of metals, e.g., in a layered shape. The layered shape may be a sheet or a foil. In an example, the SCE comprises a wrapped aluminum foil, covered by a carbon tape comprising a copper film. The copper surface can be exposed to the ambient environment. The tacky interface (e.g., carbon tape) can be disposed between the two metal, e.g., of the different type. The metal closer to the cell assembly may be a wrapped sheet (e.g., foil) such as an aluminum foil. One of the metal may have the good (e.g., superior) electrical conductivity, e.g., as disclosed herein. In an example, the metal comprises copper. The metal may provide a high-conductivity path for discharge, superior electrical interface between the SCE and the conductive foreign object, superior electrical interface between the SCE and the SCCE, superior electrical interface between the SCE and the tacky interface, and / or current redirection. The adhesive interface (e.g., layer) may maintain structural cohesion during thermal cycling and / or mechanical impact. The tacky interface may comprise carbon-based material. The interface may promote surface compliance and / or contact uniformity during foreign object penetration. The shield structure may be positioned externally to the enclosure enclosing the cell assembly. The shield may be electrically coupled with the electrode (e.g., cathode) terminal of the cell assembly. The layering of the shield sequence may be selected to initiate (e.g. harmful) discharge events away from the cell assembly zone.

[0192] Fig. 14 illustrates a schematic example 1400 and a photographic example 1450. Example 1400 shows a schematic view of a laminated electrode structure comprising a copper foil 1402 and a conductive tacky layer 1404. The copper foil 1402 is disposed above the conductive tacky layer 1404. In an example, the conductive tacky layer 1404 is a carbon tape. Example 1450 shows a cross-sectional microscopic (e.g., SEM) image of the laminatedstructure. A top region 1452 corresponds to the ambient environment. Region 1454 corresponds the copper foil. A lower region 1456 corresponds to the conductive tacky material comprising the conductive carbon particles, that together form the tacky interface 1454. The layered structure shown in examples 1400 and 1450 is representative of a shield-coupled electrode geometry comprising a contact-enhancing carbon interface. Image 1450 was taken from a carbon tape having a copper foil attached to it, that has a thickness of about 100 micrometers.

[0193] In some embodiments, a method of fabricating a shielded electrochemical device may comprise preparing an electrochemical cell and a set of shielding components. The method may comprise electrically coupling a shield-coupled electrode (SCE) and / or a shield-coupled counter-electrode (SCCE) to respective terminal tabs of the cell assembly. The method may comprise arranging a tacky interface and one or more (e.g., protective and / or conductive) outer layers. The method may comprise sealing the assembled construct. The sequence of fabrication operations may vary based at least in part on structural configuration. The SCE and / or the SCCE may be applied in multiple layers, wraps, or other architectures, based at least in part on shielding geometry. The fabrication parameters may be adjusted based at least in part on discharge dissipation behavior. The method may conclude once the shielding system and cell assembly are integrated into a durable construct.

[0194] In some embodiments, an example 1500 of fabricating a construct is initiated as shown in Fig. 15. The method comprises optionally preparing electrolytic cell and shielding components, in block 1501 ; providing electrolytic cell and shielding components, in block 1502; electrically coupling SCE and SCCE to respective terminal tabs, in block 1504; optionally arranging a tacky interface, outer protective interface, and / or outer conductive interface, in block 1506; and providing the construct, e.g., for nail penetration testing, in block 1508. In some embodiments, the SCCE (e.g., the constraint system) is coupled with its respective terminal tab as part of the construction of the cell assembly in its enclosure. The preparation of the construct may comprise receiving the enclosure of the cell assembly (e.g., with the SCCE coupled with the electrode terminal tab), coupling the SCE to the enclosure, and coupling the SCE to the counter-electrode terminal tab.

[0195] In some embodiments, an electrochemical cell and / or associated shielding components are prepared for fabricated the shielded construct. The preparation may include forming the cell assembly (e.g., at least in part by stacking electrode layers with their separators), coupling terminal tabs to the cell assembly (e.g., at least in part by using busbars), placing the cell assembly in an enclosure, and loading electrolyte into the enclosure from which sections of each of the terminal tabs emerge. The preparation may include adding components of the shield system. At least one component can be disposed in the enclosure, at the enclosure, or outside of the enclosure. The shielding components may comprise theshield-coupled electrode (SCE), the shield-coupled counter-electrode (SCCE), the optional tacky interface (e.g., layer), and the shield separator. The SCE and / or SCCE may be selected based at least in part on mass, FLS, and / or thermal conductivity. The prepared subassemblies may be aligned with (e.g., anticipated) penetration pathway of the foreign object and / or energy dissipation design requirements.

[0196] In some embodiments, the SCE and / or SCCE are electrically coupled with respective terminals of the cell. The coupling may be formed by (i) welding, (ii) conductive lamination, (iii) pressure contact, and / or (iv) metal bonding. The coupling may be any coupling disclosed herein, e.g., that facilitates electrical conductance therethrough. The SCE may be coupled with the cathode terminal, and the SCCE may be coupled with the anode terminal, or vice versa. The electrical continuity between the cell assembly and the shield system, may be maintained during the prescribed lifetime of the device, across thermal cycling, mechanical load, and / or discharge conditions. The coupling geometry may be selected at least in part to minimize resistance and / or to enable discharge outside the cell assembly region.

[0197] In some embodiments, the tacky interface and / or outer shield surface, may be arranged for fabrication of the construct. The arrangement may comprise (i) laminating (e.g., carbon) tape, (ii) wrapping with conductive material (e.g., copper foil), (iii) inserting a dielectric layer as the shield separator, and / or (iv) positioning an extended shield mass (e.g., as a wrapped layer, or as a bulk slab). The tacky interface may promote contact uniformity, e.g., during foreign object penetration. The outer (e.g., protective and / or conductive) surface may cover at least partial (e.g., full) enclosure surface(s). The stack order of the shield system’s components may control discharge location and / or delay thermal propagation into the cell assembly.

[0198] In some embodiments, the enclosure is sealed. The sealing may comprise (i) folding laminated shields, (ii) enclosing the assembly in a polymer-metal film, (iii) heat-sealing edges, and / or (iv) integrating compression plates. The enclosure may enclose the SCE, SCCE, tacky layer, and / or the cell assembly (with its electrolyte mix). The seal may provide vapor isolation, liquid isolation, and / or mechanical retention. The configuration may define a boundary condition for discharge dissipation externally to the cell assembly.

[0199] In some embodiments, the construct comprises several SCEs and / or several SCCEs. In a construct, the arrangement of the SCE and / or SCCE, may be repeated, e.g. based at least in part on shielding geometry. The repetition may address several cell stacks, layer segmentation, various electrode orientations, various electrode geometries, and / or extended enclosure formats. The shield pair may be repeated, e.g., at periodic, or at non - periodic, intervals such as along the length or height of the enclosure. The repeated configuration may enable uniform discharge interception and / or consistent electrical polarity distribution, e.g., across modular regions.

[0200] In some embodiments, fabrication parameters are adjusted based at least in part on energy dissipation behavior. The adjustment may involve modifying shield thickness, tuning tacky material coverage, repositioning discharge barriers, and / or scaling FLS values. The scaling of FLS values may be for discharge and / or thermal control. The parameters may be altered based at least in part on simulation results (e.g., physics and / or chemistry based simulations) and / or physical test feedback. The updated structure may improve discharge localization and / or minimize thermal interaction with the cell assembly.

[0201] Fig. 16 illustrates a fabrication example 1600 for a shield-integrated secondary battery. At block 1602, an electrode assembly is produced having unit cells stacked in a stacking direction. Each unit cell includes an anode structure, a separator structure, and a cathode structure. At block 1604, a secondary battery is produced by inserting the electrode assembly and an electrolyte into a battery enclosure. At block 1608, the battery is wrapped with one or more layers of metal foil. The metal foil includes a defined foil length and at least one wrap of a carbon-based double-sided tape having a copper foil. The wrap structure includes a tacky carbon interface and may serve as a shield-coupled electrode (SCE). The arrangement defines a conductive and compliant arc interception region external to the battery enclosure. The wrapped foil layer demonstrates a single wrap shielding configuration tuned for external arc closure.

[0202] In some embodiments, the device comprises a shielding system forming a construct. The shielding system may include the shield-coupled electrode (SCE) and / or the shield- coupled counter-electrode (SCCE). The SCE and / or the SCCE may be positioned relative to the cell assembly. A shield separator may be disposed between the SCE and the SCCE. The SCE and the SCCE may be each electrically coupled with a respective terminal tab of the cell assembly. The shielding system may conduct discharge before a foreign object reaches the cell assembly. The SCCE may receive the arc within a region offset from the cell assembly. The configuration may reduce thermal runaway without using fuse elements and / or (e.g., active) circuit interrupters. The structure may be compatible with lamination, enclosure sealing, and / or welding. The system may satisfy commercial safety standards and / or jurisdictional standards pertaining to the device, e.g., as disclosed herein. The shielding arrangement may (e.g., substantially) preserve, or minimally disrupt, energy density of the device. The SCE, the SCCE, and / or the shield separator may act together to localize discharge behavior. The SCE, the SCCE, and / or the shield separator may act together to enable coordinated protection of the electrochemical cell assembly.

[0203] In some embodiments, the energy manipulation device (e.g., battery) is utilized for providing energy to electrical devices. The device(s) may include smartphone, tablet, wearable electronics (watches, glasses, health tracks), power bank (e.g., for mobile devices), micro portable devices (drones, cameras, smart card), mobile Wi-Fi, Bluetooth headset, smarthome related device (loTs), electric toothbrushes, precision grooming tools, small-scale gardening equipment, (e.g., service) robots, (e.g., compact) medical such as chest compression, cosmetics, (e.g., compact) exercise, other wellness devices, learning tools, UAVs (drones) such as for short distance, e.g., racing, short distance, and military drones, torpedoes, and missiles. Also, Helicopter, and other industrial equipment, online baking tools (e.g., a bank llkey), Bluetooth enable devices, EVs (e.g., including consumer, bikes, race cars, scooters), body worn vests, warmers, coolers, cameras, Internet of Things (loTs), Wearables, watches, e-cigarette, augmented reality (AR) glasses, virtual reality (VR) glasses, sensors, hearing devices, smart glasses, or any combination thereof. The device may be utilized for any battery powered electronic product. The robots may be service robots for cargo, e.g., maneuvering. The cargo maneuvering may be within a facility, or between facilities. The robot may comprise a warehouse robot. The EV cargo UAV. The EV may comprise a UAV. The energy manipulation device may be utilized for control. The energy manipulation device may be utilized for video streaming, e.g., MP3 player. The drone may be an underwater drone and / or an aerial drone.

[0204] In some embodiments, the device is manufactured. The device 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 lower concentration of reactive agent, a higher temperature, or a higher pressure. The reactive agent may react with one or more components of the device, e.g., during its use, storage, shipping, maintenance, and / or fabrication. The cells may be fabricated according to any configuration disclosed herein, and using any material disclosed herein, as appropriate. The tabs may be folded, welded, adhered to a tacky connector, and / or adhered to a solid busbar. The manufacture process (e.g., of any component disclosed herein) may comprise printing, stenciling, heat application, heat transfer, any combination thereof, or any plurality thereof, as applicable. The application may comprise deposition. The printing may comprise stencil printing, direct printing, or sublimation printing. One or more operations of the manufacturing may be controlled by a control system, e.g., comprising at least one controller such as any control system disclosed herein.

[0205] In some embodiments, the cells are manufactured, e.g., to form a battery. An insulator and / or adhesive (e.g., tacky material) may be applied such as at a glass or at a melting temperature of at least one component of the adhesive, e.g., at a temperature of at least about 100°C, 150°C, 200°C, or 250°C. The application of the adhesive and / or insulator can be at least at ambient pressure, or above ambient pressure, e.g., at a pressure of at least about 14.5psi, 14.7psi, 20 psi, or 25psi. The adhesive and / or insulator may harden. The adhesive and / or insulator may have a thickness of at least about 50 pm, 100 pm, or 150 microns (pm).The adhesive and / or insulator may have a resistance, e.g., of at most about 0.1 milliohms (mQ), 0.2 mQ, 0.5 mQ, 1 mQ, or 2 ohms (Q).

[0206] 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 generate control signals responsive to the measurement data collected by the metrological detection system.

[0207] In some embodiments, the systems, apparatuses, devices, and / or components thereof disclosed herein comprise one or more controllers. The one or more controllers can comprise one or more central processing unit (CPU), input / output (I / O) and / or communications module. The CPU can comprise electronic circuitry that carries out instructions of a computer program by performing arithmetic, logical, control and I / O operations specified by the instructions. The controller can comprise a suitable software (e.g., operating system). The control system may optionally include a feedback control loop and / or feed-forward control loop. The controllers may be shared between one or more systems or apparatuses. Each apparatus or system may have its own controller. Two or more systems and / or their components may share a controller. Two or more apparatuses and / or its components may share a controller. The controller may monitor and / or direct (e.g., physical) alteration of the operating conditions of the apparatuses, software, and / or methods described herein. The controller may be a manual or a non-manual controller. The controller may be an automatic controller. The controller may operate upon request. The controller may be a programmable controller. The controller may be programed. The controller may comprise a processing unit (e.g., CPU or GPU). The controller may receive an input (e.g., from a sensor). The controller may deliver an output. The controller may comprise multiple controllers. The controller may receive multiple inputs. The controller maygenerate 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. The control system may use control protocols, e.g., including modbus, Open Platform Communication Unified Architecture (OPCUA), EhterNet / IP, PROFINET, Profibus, MQTT, EtherCAT, IO-Link, FANUC FOCAS, and / or LSV / 2, as applicable. The control system may utilize control logic, e.g., including programmable logic controllers (PLCs), Supervisory Control and Data Acquisition (SCADA), Distributed control systems (DCS), integrated automation systems, and / or edge computing and Industrial Internet of Things (lloT), as applicable. The control may include machine to machine control, user to machine control (e.g., user provides input to machine), or machine to user control (e.g., providing input to a user). The control system may utilize controller area network (CAN) and / or CAN open protocols.

[0208] Fig. 17 shows a schematic example of process 1720 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 1705 to comparator 1706 that generates an error signal, which is fed 1745 into controller 1740. In other control systems, the comparator can be part of the controller. Controller 1740 generates a control signal that is fed into controlling element 1730. The controlling element may comprise a mechanism utilized for its control function to control process 1720. Controlling element 1730 provides an input to process 1720. The mechanism may effectuate a physical and / or a chemical change, which change is the input to process 1720. 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 1720 can be any process disclosed herein, e.g., any method such as a fabrication (e.g., manufacturing) method. Process 1720 generates an output detected by measuring element 1710, e.g., using its sensor(s). The output provided by process 1720 may be a reaction of the process to the input provided by control element 1730.Measuring element 1710 generates a variable amplitude signal that is fed back into comparator 1706 and is again compared with the setpoint. Measuring element 1710 optionally also generates a controlled variable 1781. Control element 1730 optionally also receives a manipulated variable 1782, e.g., from an external source such as a processor and / or a communication system. Sensor(s) can be used by measuring element 1710 for the measurement of parameters of the process, e.g., 1720. The sensor measurement can be a determination of an amplitude of a parameter such as of a material, e.g., as disclosed herein. In an example, the value of the measurement is consistent and repeatable. The sensor(s) can convert the physical parameters (e.g., repeatedly, and reliably) into a usable form by the control system, e.g., into an electrical signal such as in a digital form. The comparator can perform an error detection, e.g., by determining a difference between the amplitude of the measured variable and a requested set reference point (e.g., set point 1705), 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., 1740), 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-) processor-based 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., 1740) 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., 1730. The controller can monitor input signal(s). The input signals may be interrelated. The controller may direct at least two control elements in concert. The controller may direct at least two control elements simultaneously. The controller may direct at least two control elements sequentially. The control element (e.g., 1730) can be a device that controls an incoming material to the process, or any other attribute of the process comprising a physical attribute or a chemical attribute. The physical attribute may comprise mechanical, magnetic, piezoelectric, electromagnetic, electrical, pressure, or temperature attribute. The chemical attribute may comprise a chemical gradient, or in a chemical entity. The control element can be a flow control element. The control element can be a temperature control element. The control element can have toggle (e.g., On / Off) characteristics. The control element can provide linear, or non-linear, control of the control element. The control element can be used to adjust the input to the process, e.g., bringing the output variable to the value of the set point. The measuring element (e.g., 1710) can consist of sensor(s) to measure the physical property of a variable, a transducer to convertthe sensor signal into an electrical signal, and / or a transmitter to amplify the electrical signal. The amplification of the signal can be transmitted with minimal (e.g., without measurable) loss. The control element may comprise an actuator which changes the electrical signal from the controller into a signal to operate and / or control a physical device such as a valve. The controller may comprise a memory or be operatively coupled with a memory. The control system may comprise a summing circuit, e.g., to compare the set point to the sensed signal, so that it can generate the error signal. The summing circuit may be part of the comparator. The controller may use the error signal to generate a correctional signal to control the control element. In an example, the controller controls a valve via an actuator and the input variable. The sensors of the measuring element may comprise optical sensors, temperature sensors, pressure sensors, chemical sensors, proximity sensors, viscosity sensors, chemical sensors, or any other sensor disclosed herein. The chemical sensors may sense a material comprising oxygen, water, or any other reactive agent(s) herein. The sensors may sense one or more attributes of the methods disclosed herein such as the fabrication methods. Control may comprise regulate, modulate, adjust, maintain, alter, change, govern, manage, restrain, restrict, direct, guide, oversee, manage, preserve, sustain, restrain, temper, or vary.

[0209] 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. 18 shows a schematic example of a computer system 1800 that is programmed or otherwise configured to facilitate execution any of the methods provided herein. The computer system 1800 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 1800 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 1800 can include a processing unit 1806 (also “processor,” “computer” and “computer processor” used herein). The computer system may include memory or memory location 1802 (e.g., randomaccess memory, read-only memory, flash memory), electronic storage unit 1804 (e.g., hard disk), communication interface 1803 (e.g., network adapter) for communicating with one or more other systems, and peripheral devices 1805, such as cache, other memory, data storage and / or electronic display adapters. The memory 1802, data storage unit 1804, interface 1803, and peripheral devices 1805 are in communication with the processing unit 1806 through acommunication 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”) 1801 , e.g., with the aid of the communication interface. The network can be the Internet, an internet and / or extranet, or an intranet and / or extranet that is in communication with the Internet. In some cases, the network is a telecommunication and / or data network. The network can include one or more computer servers, which can enable distributed computing, such as cloud computing. The network, in some cases with the aid of the computer system, can implement a peer-to-peer network, which may enable devices coupled with the computer system to behave as a client or a server. The processing unit 1806 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 1802. The instructions can be directed to the processing unit 1806, 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 1806 can include fetch, decode, execute, and write back. The processing unit 1806 may interpret and / or execute instructions. The processing unit 1806 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 1806 can be part of a circuit, such as an integrated circuit. One or more other components of the system (e.g., 1800) can be included in the circuit.

[0210] In some embodiments, the storage unit (e.g., 1804) 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 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.

[0211] In some embodiments, the system, device, and / or apparatus disclosed herein comprises communicating through a network. The computer system can communicate with one or more remote computer systems through a network. For instance, the computer system can communicate with a remote computer system of a user (e.g., operator). Examples of remote computer systems include personal computers (e.g., portable PC), slate or tablet PC's (e.g., Apple® iPad, Samsung® Galaxy Tab), telephones, Smart phones (e.g., Apple® iPhone, Android-enabled device, Blackberry®), or personal digital assistants. A user (e.g., client) can access the computer system via the network.

[0212] In some embodiments, the computer system 1800 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 1802 or electronic (e.g., data) storage unit 1804. The machine executable or machine-readable code can be provided in the form of software. During use, the processor (e.g., 1806) 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 machineexecutable instructions are stored on memory. The code can be pre-compiled and configured for use with a machine that has a processor 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.

[0213] In some embodiments, the computer system 1800 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 ofholes, a RAM, a ROM, a PROM and EPROM, a FLASH-EPROM, any other memory chip or cartridge, a carrier wave transporting data or instructions, cables or links transporting such a carrier wave, any other medium from which a computer may read programming code and / or data, or any combination thereof. The memory and / or data storage may comprise a storing device external to and / or removable from device, such as a Universal Serial Bus (USB) memory stick, and / or a hard disk. Many of these forms of computer readable media may be involved in carrying one or more sequences of one or more instructions to a processor for execution.

[0214] 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.

[0215] In some embodiments, the construct is structured with a modular configuration for sheet handling and / or processing. The manufacturing system may comprise (i) a roll mounting assembly for raw material supply, (ii) a measurement unit for real-time thickness control, and / or (iii) a sectioning module equipped with automated cutting tools. The cutting tools may comprise cleaning and / or precision tools. Each subcomponent may be supported on dedicated structural elements to ensure process stability and / or reliability during high- throughput operations.

[0216] Example 1 : A series of penetration experiments were conducted using a cell assembly comprising an LCO-based cathode and a silicon-based anode (e.g., SiOx), having an assembly similar to that depicted in Figs. 5-6. The cathode active material was coated onto an aluminum current collector. The anode active material was coated onto a copper current collector. The electrodes were stacked and enclosed in a sealed pouch comprisingpolyethylene laminate and an aluminum layer disposed therein. A stainless-steel constraint system (SS301) was coupled with the anode terminal tab. The constraint was coated with ClearClad and positioned to mechanically constrain the interior of the pouch. The constraint system coupled with the cell assembly, was protected by a pouch protection layer, e.g., to lessen a probability of the constraint system puncturing the pouch from within. An aluminum foil wrap was placed around the exterior of the pouch and electrically coupled with the cathode terminal tab. A copper film bearing a layer of carbon tape as shown in Fig 14, 1450, was applied over the aluminum wrap such that the copper film was exposed to the ambient environment and the carbon tape faced the aluminum wrap, e.g., in a manner similar to that depicted in fig. 13. The copper-carbon layer functioned as a contact-enhancing interface with the penetrating foreign object - a metallic nail. The combined external structure of aluminum wrap- carbon tape-copper foil, formed the SCE for nail penetration testing. A stainless-steel nail was driven through the external structure to evaluate energy discharge behavior. The nail first penetrated the copper film, followed by the carbon tape layer. The nail then passed through the aluminum foil wrap, which was electrically coupled with the cathode terminal tab and thereby held cathodic potential of the cell assembly within the pouch. The nail next entered the laminate pouch and penetrated the internal region of the pouch, e.g., also enclosing an electrolyte mix. The final penetration stage reached the stainless-steel constraint acting as the SCCE, which was electrically coupled with the anode terminal tab and held anodic potential of the cell assembly. The pouch structure included a layered structure comprising polyethylene film and aluminum barrier layer. The test sequence was held constant in each experiment. The length of the aluminum wrap was varied to assess the effect of SCE mass on thermal response. Wrap lengths of the aluminum film tested, were 55 cm, 65 cm, 70 cm, 75 cm, and 80 cm, results of which are described in examples 2-6. Discharge generation, thermal runaway, and peak temperature were recorded for each test. The cupper-carbon tape was wrapped ones along successive sides of the prismatic pouch, e.g., as depicted in Fig. 13.

[0217] Example 2: The SCE comprises an aluminum wrap of 55 cm in length. The nail penetration proceeded through all external and internal layers of the shield system as described in example 1. Thermal runaway occurred. The maximum recorded temperature exceeded 400°C.

[0218] Example 3: The SCE comprises an aluminum wrap of 65 cm in length. The nail penetration proceeded through all external and internal layers of the shield system as described in example 1. The nail penetration reached the constraint layer. Thermal runaway was observed. The peak temperature again exceeded 400°C.

[0219] Example 4: The SCE comprised an aluminum wrap of 70 cm in length. The nail penetration proceeded through all external and internal layers of the shield system asdescribed in example 1. No thermal runaway occurred. The maximum temperature recorded was 104°C.

[0220] Example 5: The SCE comprised an aluminum wrap of 75 cm in length. The nail penetration proceeded through all external and internal layers of the shield system as described in example 1. The penetration test resulted in no thermal runaway. The maximum temperature recorded was 98°C.

[0221] Example 6: The SCE comprises an aluminum wrap of 80 cm in length. The nail penetration proceeded through all external and internal layers of the shield system as described in example 1. The test did not result in thermal runaway. The maximum temperature recorded was 84°C.

[0222] The test results indicate a correlation between SCE mass and thermal suppression. Shorter aluminum wraps of 55 cm and 65 cm resulted in thermal runaway and flame generation. Longer wraps of 70 cm, 75 cm, and 80 cm accounting for greater aluminum mass, prevented ignition. Peak temperatures declined with increasing SCE length. The cathodic aluminum wrap and anodic stainless-steel constraint formed an external discharge path prior to cell assembly breach. The increased aluminum mass expanded the charge-absorption region along the foreign object’s path. The spatial arrangement enabled discharge containment outside the cell assembly zone. The experimental data support that external SCE mass and geometry can be tuned to suppress thermal failure without altering internal chemistry or requiring active circuit protection.

[0223] As illustrated in Figs. 12-14 and discussed above, systems and methods are disclosed herein wrapping a battery cell with long enough thin metal foil and welding the foil to one of the cell tabs to redirect the shorting current after nail penetration to the metal foil, preventing a hot spot and thermal runaway. In some embodiments, the systems and methods disclosed herein allow for passing of the nail penetration safety tests without any negative impact on cell performance (i.e. , cycle life, rate capability, and high and low temperature performance) - the only drawback being an energy density reduction due to the addition of inactive material to the cell thickness.

[0224] In another aspect, the systems and methods disclosed herein include a process for manufacturing electrodes of a secondary battery using a rotary die assembly. As shown in Fig. 16, the process begins by producing an electrode assembly having unit cells stacked in a stacking direction, each of the unit cells having an anode structure, a separator structure, and a cathode structure. The process continues by producing a secondary battery having a battery enclosure, and the electrode assembly and an electrolyte within the battery enclosure. The process finishes by wrapping the secondary battery with wraps of a metal foil having a metal foil length and at least one wrap of a carbon double-sided tape having a copper foil. In some embodiments, the metal foil is an aluminum metal foil.

[0225] In another aspect, the systems and methods disclosed herein include a secondary battery having a battery enclosure, and an electrode assembly and an electrolyte within the battery enclosure. The electrode assembly having unit cells stacked in a stacking direction, each of the unit cells comprising an anode structure, a separator structure, and a cathode structure. The secondary battery having several wraps of a metal foil having a metal foil length, and at least one wrap of a carbon double-sided tape having a copper foil. The systems and methods discussed herein can be modified by adjusting the thickness and / or width of the foil. In addition, the systems and methods discussed herein can be modified by changing the material of the foil in addition to the aluminum and copper discussed above.

[0226] The processes discussed above are intended to be illustrative and not limiting. One skilled in the art would appreciate that the steps of the processes discussed herein may be omitted, modified, combined, and / or rearranged, and any additional steps may be performed without departing from the scope of the invention. More generally, the above disclosure is meant to be exemplary and not limiting. Furthermore, it should be noted that the features and limitations described in any one embodiment may be applied to any other embodiment herein, and flowcharts or examples relating to one embodiment may be combined with any other embodiment in a suitable manner, done in different orders, or done in parallel. In addition, the systems and 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.

[0227] 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

1. CLAIMSWhat is claimed is:1 . A device for conducting electricity, the device comprising: a cell assembly comprising one or more unit cells, the cell assembly comprising an electrode and a counter-electrode, the electrode comprising electrode active material coupled with an electrode current collector, the counter-electrode comprising counter-electrode active material coupled with a counter-electrode current collector the electrode current collector being electrically coupled with an electrode terminal tab and the counter-electrode current collector being electrically coupled with a counter-electrode terminal tab, each of the electrode terminal tab and the counter-electrode terminal tab being configured to couple with an external source for conducting the electricity relative to the cell assembly; a counter-electrode shield electrically coupled with the counter-electrode terminal tab, the counter-electrode shield being electrically conductive, the counter-electrode shield being disposed external to the cell assembly, the counter-electrode shield being physically coupled with the cell assembly; an electrode shield electrically coupled with the electrode terminal tab, the electrode shield being electrically conductive, the electrode shield being disposed external to the cell assembly, the electrode shield being physically coupled with the counter-electrode shield, the electrode shield being separated from the counter-electrode shield by a gap, the electrode shield being disposed further away from the cell assembly relative to the counter-electrode shield; and a shield separator disposed between the electrode shield and the counter-electrode shield, the shield separator being disposed in the gap, the shield separator comprising an electrically insulating material, the electrode shield and the counter-electrode shield being configured such that a foreign object that progresses in a path towards the cell assembly, will successively penetrate the electrode shield, the shield separator, and the counter-electrode shield to cause an electrical short that discharges electrical energy outside the cell assembly, before the foreign object reaches the cell assembly.

2. The device of claim 1 , wherein the cell assembly comprises (i) a stacked architecture comprising a plurality of unit cells arranged along a stacking axis, (ii) a wrapped cell architecture comprising a wound electrode-separator structure, or (iii) any combination thereof.

3. The device of claim 1 , wherein the electrode comprises a cathodically active material comprising cobalt, a metal oxide, any plurality of types thereof, or any combination thereof.

4. The device of claim 1 , wherein the counter-electrode comprises an anodically active material comprising silicon or an allotrope of elemental carbon.

5. The device of claim 1 , wherein the electrode active material comprises cobalt, lithium, iron, phosphate, or an allotrope of elemental carbon.

6. The device of claim 1 , wherein the electrode current collector is electrically coupled with the electrode terminal tab at least in part by welding, by using a tacky conductive material, any plurality of types thereof, or any combination thereof.

7. The device of claim 1 , wherein the electrode terminal tab and the counter-electrode terminal tab are each configured to couple with an external system comprising an electrical power source and / or an electrical device.

8. The device of claim 1 , wherein the cell assembly is disposed in a housing comprising an insulating material.

9. The device of claim 1 , wherein the counter-electrode shield comprises a constraint system electrically coupled with the counter-electrode terminal tab, the constraint system comprising an elemental metal, a metal alloy, an allotrope of elemental carbon, any plurality of types thereof, or any combination thereof.

10. The device of claim 1 , wherein an insulator is disposed between the cell assembly and the counter-electrode shield comprising the constraint system.

11. The device of claim 1 , wherein the electrode shield comprises a structure devoid of particulate material, a sheet, a foil, a layered structure, a wound structure disposed about an axis while enveloping the cell assembly to form an envelope, the counter-electrode shield, or any combination thereof.

12. The device of claim 1 , wherein the shield separator comprises an electrically insulating material.

13. The device of claim 1 , wherein the electrode shield and the counter-electrode shield, (A) are disposed outside of the cell assembly and / or (B) are configured to cause discharge of electrical energy resulting from a foreign object penetration to occur outside the cell assembly, the discharge being initiated between the electrode shield and the counter-electrode shield.

14. A method of testing the device of claims 1-13, the method comprising: (a) providing the device; and (b) inserting the foreign object into the device such that the foreign object (i) penetrates the electrode shield and the counter electrode shield on its way to the cell assembly and (ii) penetrates the cell assembly.

15. An apparatus for testing the device of claims 1-13, the apparatus comprising at least one controller configured to direct one or more operations for assembling the device of claims 1- 13, the operations comprising: (a) providing the device; and (b) inserting the foreign object into the device such that the foreign object (i) penetrates the electrode shield and the counter electrode shield on its way to the cell assembly and (ii) penetrates the cell assembly.

16. Non-transitory computer-readable program instructions physically inscribed on at least one medium, the program instructions, when read by one or more processors operatively coupled with the device of claims 1-15, cause the one or more processors to execute one or more operations for preparing the device, the one or more operations comprising: (a) providing the device; and (b) inserting the foreign object into the device such that the foreign object (i) penetrates the electrode shield and the counter electrode shield on its way to the cell assembly and (ii) penetrates the cell assembly.

17. A method of manufacturing the device of claims 1-15, the method comprising: (a) providing components the cell assembly; and (b) electrically coupling the electrode shield with the cell assembly at least in part by coupling the electrode shield with the electrode terminal tab.

18. An apparatus for manufacturing the device of claims 1-15, the apparatus comprising at least one controller configured to direct one or more operations for assembling the device, the operations comprising: (a) providing the cell assembly; and (b) electrically coupling the electrode shield with the cell assembly at least in part by coupling the electrode shield with the electrode terminal tab.

19. Non-transitory computer-readable program instructions physically inscribed on at least one medium, the program instructions, when read by one or more processors operatively coupled with the device of claims 1-15, cause the one or more processors to execute one or more operations for preparing the device, the operations comprising: (a) providing the cell assembly; and (b) electrically coupling the electrode shield with the cell assembly at least in part by coupling the electrode shield with the electrode terminal tab.

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