Method for preparing battery assembly and battery assembly prepared thereby

Abstract

Disclosed is a method of preparing an assembly of a battery with a high yield. In some embodiments, the method comprises laminating one pre-pressed unit of a first type over one or more pre-pressed units of a second type, wherein the first type and the second type have a different configuration, the bottom of the pre-pressed unit of the first type is functionally complementary to the top of the pre-pressed unit of the second type without structural redundancy at the interface between adjacent units. In some embodiments, the bottom of a first pre-pressed unit of the second type is functionally complementary to the top of a second pre-pressed unit of the second type with no structural redundancy at interface therebetween.

Description

METHOD FOR PREPARING BATTERY ASSEMBLY AND BATTERY ASSEMBLY PREPARED THEREBYCROSS-REFERENCE

[0001] The present application claims the benefit of US Serial No. 63 / 667,391, filed July 3, 2024, the entire content of which is incorporated herein by reference into this application.FIELD

[0002] This disclosure generally relates to a method for preparing a battery assembly and battery assemblies prepared thereby.BACKGROUND

[0003] In comparison to conventional batteries with liquid electrolytes, all solid-state batteries (ASSBs) employ solid electrolytes which exhibit a better safety profile because it is free of liquid electrolyte leakage. Assembly of solid electrolyte (SE) with electrodes is challenging due to solid-solid interface. To reduce the SE / electrode interfacial resistance, a compression is usually applied to a stack of cell components to keep the solid electrolyte and electrode in intimate contact with each other. A mechanical pressing or an isostatic pressing is usually performed to bring the cell components together. An isostatic pressing utilizes a fluid medium such as oil, water or gas to compress a cell sealed in a pouch. However, such isostatic pressing can only be used for a small cell or assembly. Once the cell size is relatively big, it is too big to fit into the chamber for the isostatic pressing. Mechanical pressing has to be used for a large cell, which leads to a low yield due to occurrence of damage during compression. Thus, there remains a need for a new design and method to prepare cell assembly with a high yield.SUMMARY

[0004] Disclosed is a method of preparing an assembly of a battery with a high yield. The method comprises laminating one pre-pressed unit of a first type over one or more pre-pressed units of a second type, wherein the first type and the second type have a different configuration, the bottom of the pre-pressed unit of the first type is functionally complementary to the top ofthe pre-pressed unit of the second type without structural redundancy at the interface between adjacent units. In some embodiments, when there are multiple pre-pressed units of the second type, the bottom of a first pre-pressed unit of the second type is functionally complementary to the top of a second pre-pressed unit without structural redundancy at the interface therebetween. [00051 In some embodiments, the present disclosure provides a method for preparing a battery assembly comprising multiple first electrodes, multiple second electrodes, and multiple solid electrolyte (SE) layers each SE layer disposed between a first electrode and a second electrode. The method comprises: a) having a pre-pressed unit of type A which is compressed by an isostatic compression, wherein the unit of type A comprises a top first electrode current collector, a top first electroactive material layer, a top solid electrolyte layer, optionally a top second electroactive material layer, a second electrode current collector, optionally a bottom second electroactive material layer, a bottom solid electrolyte layer, a bottom first electroactive material layer and a bottom first electrode current collector in the order, b) having one or more pre-pressed units of type B, each unit of type B compressed by an isostatic compression on each of one or more units of type B, wherein each unit of type B comprises a top first electroactive material layer, a top solid electrolyte layer, optionally a top second electroactive material layer, a second electrode current collector, optionally a bottom second electroactive material layer, a bottom solid electrolyte layer, a bottom first electroactive material layer and a bottom first electrode current collector in the order, c) laminating one pre-pressed unit of type A over the one or more pre-pressed units of type B into a pre-assembly, wherein the bottom first electrode current collector in the pre-pressed unit of type A is adjacent to the top first electroactive material layer in one of the one or more pre-pressed units of type B, and d) pressurizing the pre-assembly, thereby obtaining an assembly.[0006| In some embodiments, the method comprises laminating a top first electrode current collector over one or more pre-pressed units of type B into a pre-assembly and pressurizing the pre-assembly, thereby obtaining an assembly.[00071 In some embodiments, the method as disclosed herein can lead to a yield of at least 80%, at least 85%, at least 90% or at least 95%.BRIEF DESCRIPTION OF THE FIGURES

[0008] Non-limiting embodiments of the present disclosure will be described by way of example with reference to the accompanying figures, which are schematic and are not intended to be drawn to scale. In the figures, each identical or nearly identical component illustrated is typically represented by a single numeral. For purposes of clarity, not every component is labeled in every figure, nor is every component of each embodiment of the disclosure shown where illustration is not necessary to allow those of ordinary skill in the art to understand the disclosure.

[0009] Fig. 1 is a schematic diagram showing a typical configuration of a cell assembly according to one embodiment of the present disclosure.

[0010] Fig. 2 is a schematic diagram showing a typical configuration of a cell assembly according to one embodiment of the present disclosure.

[0011] Fig. 3 is a schematic diagram showing a typical configuration of a pre-pressed unit of type A according to one embodiment of the present disclosure.

[0012] Fig. 4 is a schematic diagram showing a typical configuration of a pre-pressed unit of type A according to another embodiment of the present disclosure.

[0013] Fig. 5 is a schematic diagram showing a typical configuration of a pre-pressed unit of type B according to one embodiment of the present disclosure.

[0014] Fig. 6 is a schematic diagram showing a typical configuration of a pre-pressed unit of type B according to another embodiment of the present disclosure.[0015| Fig. 7 is a schematic diagram showing a typical configuration of a cell assembly according to one embodiment of the present disclosure.DETAILED DESCRIPTION

[0016] Disclosed herein is a method for preparing a battery assembly. The method comprises laminating one pre-pressed unit of a first type over one or more pre-pressed units of a second type, wherein the first type and the second type have a different configuration, the bottom of the pre-pressed unit of the first type is functionally complementary to the top of the pre-pressed unit of the second type without structural redundancy. In some embodiments, when there are multiple pre-pressed units of the second types, the bottom of a first pre-pressed unit of the second type is functionally complementary to the top of a second pre-pressed unit of the second type without structural redundancy at the interface between them.

[0017] In one embodiment, as shown in Fig. 1, a cell assembly (100) is prepared by laminating a pre-pressed unit of type A (10A) over one or more pre-pressed units of type B (10B) into a pre-assembly and exposing the pre-assembly to an external compression via a mechanical press, thus obtaining an assembly. In some embodiments, a unit of type A comprises a top first electrode current collector (11-1), a top first electroactive material layer (11-2), a top solid electrolyte layer (31), optionally a top second electroactive material layer (not shown), a second electrode current collector (2-1), optionally a bottom second electroactive material layer (not shown), a bottom solid electrolyte layer (32), a bottom first electroactive material layer (12-2) and a bottom first electrode current collector (12-1) in the order. In some embodiments, a unit of type B comprises a top first electroactive material layer (11-2), a top solid electrolyte layer (31), optionally a top second electroactive material layer (not shown), a second electrode current collector (2-1), optionally a bottom second electroactive material layer (not shown), a bottom SE layer (32), a bottom first electroactive material layer (12-2) and a bottom first electrode current collector (12-1) in the order. In some embodiments, each pre-pressed unit oftype A and type B is independently obtained by compressing a unit of type A or B using an isostatic pressing.

[0018] As shown in Fig. 2, a cell assembly (100) is prepared by laminating a top first electrode current collector (11-1) over one or more pre-pressed units of type B (10B) into a pre-assembly and pressurizing the pre-assembly, thereby obtaining an assembly.

[0019] With such method, the components of the cell assembly such as tabs are protected and are not damaged or disconnected due to the compression.

[0020] In some embodiments, the isostatic pressing for preparing a unit of type A and B is independently conducted at a temperature range. In some embodiments, the isostatic pressing is a cold isostatic pressing (CIP) or warm isostatic pressing (WIP). In some embodiments, the isostatic pressing is conducted at a temperature in a range from 0 °C to 150 °C, from 0 °C to 140 °C, from 0 °C to 130 °C, from 0 °C to 120 °C, from 0 °C to 110 °C, from 0 °C to 100 °C, from 0 °C to 80 °C, from 0 °C to 60 °C, from 0 °C to 40 °C, 10 °C to 150 °C, from 10 °C to 140 °C, from 10 °C to 130 °C, from 10 °C to 120 °C, from 10 °C to 110 °C, from 10 °C to 100 °C, from 10 °C to 80 °C, from 10 °C to 60 °C, from 10 °C to 40 °C, 20 °C to 150 °C, from 20 °C to 140 °C, from 20 °C to 130 °C, from 20 °C to 120 °C, from 20 °C to 110 °C, from 20 °C to 100 °C, from 20 °C to 80 °C, from 20 °C to 60 °C, from 20 °C to 40 °C, 30 °C to 150 °C, from 30 °C to 140 °C, from 30 °C to 130 °C, from 30 °C to 120 °C, from 30 °C to 110 °C, from 30 °C to 100 °C, from 30 °C to 80 °C, from 30 °C to 60 °C, or any and all ranges and subranges therebetween.

[0021] In some embodiments, the isostatic pressing for each unit has a working pressure in a range from 10 MPa to 1000 MPa, from 10 MPa to 800 MPa, from 10 MPa to 600 MPa, from 10 MPa to 400 MPa, from 10 MPa to 200 MPa, from 10 MPa to 150 MPa, from 10 MPa to 125 MPa, from 10 MPa to 100 MPa, from 10 MPa to 75 MPa, from 10 MPa to 50 MPa, from 20 MPa to 1000 MPa, from 20 MPa to 800 MPa, from 20 MPa to 600 MPa, from 20 MPa to 400 MPa, from 20 MPa to 200 MPa, from 20 MPa to 150 MPa, from 20 MPa to 125 MPa, from 20MPa to 100 MPa, from 20 MPa to 75 MPa, from 20 MPa to 50 MPa, from 30 MPa to 1000MPa, from 30 MPa to 800 MPa, from 30 MPa to 600 MPa, from 30 MPa to 400 MPa, from 30MPa to 200 MPa, from 30 MPa to 150 MPa, from 30 MPa to 125 MPa, from 30 MPa to 100 MPa, from 30 MPa to 75 MPa, from 30 MPa to 50 MPa, from 50 MPa to 1000 MPa, from 50 MPa to 800 MPa, from 50 MPa to 600 MPa, from 50 MPa to 400 MPa, from 50 MPa to 200 MPa, from 50 MPa to 150 MPa, from 50 MPa to 125 MPa, from 50 MPa to 100 MPa, from 50 MPa to 75 MPa, or any and all ranges and subranges therebetween.[00221 In some embodiments, the working pressure is loaded at a controlled rate to allow slow deformation of cell pouch and the cell laminations therein, which is critical in avoiding stress concentration thus achieving desirable consistency and uniformity. In some embodiments, the working pressure of a working fluid is increased at a rate in a range from 0.1 MPa / min to 20MPa / min, from 0.1 MPa / min to 15MPa / min, from 0.1 MPa / min to lOMPa / min, from 0.1 MPa / min to 7.5MPa / min, from 0.1 MPa / min to 5 MPa / min, from 0.1 MPa / min to 2.5 MPa / min, from 0.1 MPa / min to 1 MPa / min, from 0.1 MPa / min to 0.75 MPa / min, from 0.1 MPa / min to 0.5 MPa / min, 0.25 MPa / min to 20MPa / min, from 0.25 MPa / min to 15MPa / min, from 0.25 MPa / min to lOMPa / min, from 0.25 MPa / min to 7.5MPa / min, from 0.25 MPa / min to 5 MPa / min, from 0.25 MPa / min to 2.5 MPa / min, from 0.25 MPa / min to 1 MPa / min, from 0.25 MPa / min to 0.75 MPa / min, from 0.5 MPa / min to 20MPa / min, from 0.5 MPa / min to 15 MPa / min, from 0.5 MPa / min to 10 MPa / min, from 0.5 MPa / min to 7.5 MPa / min, from 0.5 MPa / min to 5 MPa / min, from 0.5 MPa / min to 2.5 MPa / min, from 0.5 MPa / min to 1 MPa / min, from 1 MPa / min to 20 MPa / min, from 1 MPa / min to 15 MPa / min, from 1 MPa / min to 10 MPa / min, from 1 MPa / min to 7.5MPa / min, from 1 MPa / min to 5 MPa / min, from 1 MPa / min to 2.5 MPa / min, from 2 MPa / min to 20 MPa / min, from 2 MPa / min to 15 MPa / min, from 2 MPa / min to 10 MPa / min, from 2MPa / min to 7.5MPa / min, from 2MPa / min to 5 MPa / min, or any and all ranges and subranges therebetween.

[0023] In some embodiments, the working pressure for each unit is independently maintained for a period of time in a range from 1 min to 60 min, from 2 min to 60 min, from 3 min to 60min, from 5 min to 60 min, from 10 min to 60 min, from 1 min to 50 min, from 2 min to 50 min, from 3 min to 50 min, from 5 min to 50 min, from 10 min to 50 min, from 1 min to 40 min, from 2 min to 40 min, from 3 min to 40 min, from 5 min to 40 min, from 10 min to 40 min, from 1 min to 30 min, from 2 min to 30 min, from 3 min to 30 min, from 5 min to 30 min, from 10 min to 30 min, from 1 min to 20 min, from 2 min to 20 min, from 3 min to 20 min, from 5 min to 20 min, from 10 min to 20 min, or any and all ranges and subranges therebetween.

[0024] In some embodiments, the isostatic compression for each unit of type A and type B is independently conducted prior to, concurrently with, or after heating to an elevated temperature in a range from 20 °C to 150 °C, from 30 °C to 150 °C, from 40 °C to 150 °C, from 50 °C to 150 °C, from 60 °C to 150 °C, from 70 °C to 150 °C, from 20 °C to 120 °C, from 30 °C to 120 °C, from 40 °C to 120 °C, from 50 °C to 120 °C, from 60 °C to 120 °C, from 70 °C to 120 °C, from 20 °C to 100 °C, from 30 °C to 100 °C, from 40 °C to 100 °C, from 50 °C to 100 °C, from 60 °C to 100 °C, from 70 °C to 120 °C, or any and all ranges and subranges therebetween .

[0025] In some embodiments, the first electrodes are substantially parallel to the second electrodes.

[0026] In some embodiments, the pre-assembly is pressurized by placing the pre-assembly into a vacuuming bag followed by vacuuming the vacuuming bag to a preset vacuum percentage. Vacuum percentage is a relative value of the pressure difference between atmospheric pressure (Patm) and pressure in the evacuated system (Pv) over the atmospheric pressure as the base value multiplied by 100%, i.e., (Patm - Pv) / Patm x 100%.

[0027] In some embodiments, the preset vacuum percentage is at least 99.0%, at least 99.5%, at least 99.6%, at least 99.7%, at least 99.8%, or at least 99.9%.

[0028] In some embodiments, the vacuuming bag is made of a flexible material. In some embodiments, the vacuuming bag comprises at least one selected from the group consisting of polyethene (PE), polyvinylidene chloride (PVDC), polypropylene (PP), polyvinyl chloride (PVC), polyester such as polyethylene terephthalate (PET), and polyamide (PA). In someembodiments, the vacuuming bag comprises a film made of biaxially oriented PET (BoPET) (also known as Mylar).

[0029] In some embodiments, the cell assembly may comprise a number of layers. In some embodiments, a cell assembly comprising a cell pouch and a cell stack has a thickness in a range from 1 mm to 20 mm, from 1 mm to 15 mm, from 1 mm to 10 mm, from 1 mm to 7.5 mm, from 1 mm to 5 mm, from 1 mm to 4 mm, from 1 mm to 3 mm, from 1 mm to 2.5 mm, from 1.0 mm to 2.0 mm, from 2 mm to 20 mm, from 2 mm to 15 mm, from 2 mm to 10 mm, from 2 mm to 7.5 mm, from 2 mm to 5 mm, from 2 mm to 4 mm, from 2 mm to 3 mm, from 2 mm to 2.5 mm, from 3 mm to 20 mm, from 3 mm to 15 mm, from 3 mm to 10 mm, from 3 mm to 7.5 mm, from 3 mm to 5 mm, from 3 mm to 4 mm, or any and all ranges and subranges therebetween. In some embodiments, the cell assembly has a thickness smaller than the original cell assembly. In some embodiments, the cell assembly has a thickness around 5%, 10%, 15%, or 20% lower than that of the original cell assembly prior to the isostatic compression.

[0030] In some embodiments, the tabs are made of a metal or an alloy for electrically connecting the cell assembly with an external circuit. In some embodiments, non-limiting specific metals include aluminum and copper.

[0031] In some embodiments, the cell pouch is airtight. In some embodiments, the cell pouch is made of a material selected from the group consisting of aluminum foil, aluminum foil with one surface coated with at least one polymer layer, aluminum foil with two surfaces each coated with at least one polymer layer and a combination thereof.

[0032] In some embodiments, the working fluid in the chamber does not infiltrate into the cell pouch. In some embodiments, the working fluid in the chamber does not infiltrate into a pressing bag under the isostatic pressing.

[0033] In some embodiments, the pressing bag is made of a material that can seal the bag from the working fluid. In some embodiments, the bag is made of a film. In some embodiments, the film is made of polyethylene terephthalate (PET), polyethylene (PE), PU, latex, or a mixturethereof. In some embodiments, the film is made of biaxially oriented PET (BoPET) (also known as Mylar). In some embodiments, the film of the pressing bag has a thickness in a range from 0.01 mm to 0.5 mm, from 0.01 mm to 0.4 mm, from 0.01 mm to 0.3 mm, from 0.01 mm to 0.2 mm, from 0.01 mm to 0.15 mm, from 0.01 mm to 0.10 mm, from 0.01 mm to 0.08 mm, from 0.01 mm to 0.06 mm, from 0.01 mm to 0.04 mm, from 0.02 mm to 0.5 mm, from 0.02 mm to 0.4 mm, from 0.02 mm to 0.3 mm, from 0.02 mm to 0.2 mm, from 0.02 mm to 0.15 mm, from 0.02 mm to 0.10 mm, from 0.02 mm to 0.08 mm, from 0.02 mm to 0.06 mm, from 0.02 mm to 0.04 mm, from 0.04 mm to 0.5 mm, from 0.04 mm to 0.4 mm, from 0.04 mm to 0.3 mm, from 0.04 mm to 0.2 mm, from 0.04 mm to 0.15 mm, from 0.04 mm to 0.10 mm, from 0.04 mm to 0.08 mm, from 0.04 mm to 0.06 mm, from 0.05 mm to 0.5 mm, from 0.05 mm to 0.4 mm, from 0.05 mm to 0.3 mm, from 0.05 mm to 0.2 mm, from 0.05 mm to 0.15 mm, from 0.05 mm to 0.10 mm, from 0.05 mm to 0.08 mm, or any and all ranges and subranges therebetween.

[0034] In some embodiments, the film comprises PE reinforced with a polymer fiber such as nylon with a diameter in a range from 5 pm to 1000 pm, from 5 pm to 750 pm, from 5 pm to 500 pm, from 5 pm to 250 pm, from 5 pm to 100 pm, from 5 pm to 75 pm, from 5 pm to 50 pm, from 5 pm to 25 pm, from 10 pm to 1000 pm, from 10 pm to 750 pm, from 10 pm to 500 pm, from 10 pm to 250 pm, from 10 pm to 100 pm, from 10 pm to 75 pm, from 10 pm to 50 pm, from 10 pm to 25 pm, from 25 pm to 1000 pm, from 25 pm to 750 pm, from 25 pm to 500 pm, from 25 pm to 250 pm, from 25 pm to 100 pm, from 25 pm to 75 pm, from 25 pm to 50 pm, or any and all ranges and subranges therebetween.

[0035] In some embodiments, the working fluid is a liquid or a gas. Non-limiting specific fluids include water, oil, argon, air, nitrogen, carbon dioxide, and a mixture thereof.

[0036] In some embodiments, the cell assembly is a cell assembly of an all solid-state battery (ASSB). In some embodiments, the method as described herein is for preparing a cell assembly of an ASSB.

[0037] In some embodiments, the ASSB comprises a cell stack containing a solid electrolyte in at least one of the one or more electrolyte layers.

[0038] In some embodiments, the solid electrolyte includes a polymer solid electrolyte, an oxide-based solid electrolyte, a sulfide-based solid electrolyte, and any combination thereof.

[0039] In some embodiments, the solid electrolyte is an oxide-based solid electrolyte or a sulfide-based electrolyte. In one embodiment, the solid electrolyte has a formula LixMlyM2zPi-PM3pS6-a-b-qOqClaBrb (Formula I), wherein 4<x<8, 0<y<l, 0<z <1, 0<p<l, 0<q<l, 0<a<2, 0<b<2, 0<6-a-b-q<6, 0<l-p<l, wherein Ml is at least one element of Group 1 or Group 11 other than H or Li of the periodic table, M2 is at least one element of Group 2 of the periodic table, and M3 is at least one element of Group 14 of the periodic table.

[0040] In some embodiments, the solid electrolytes has a formula LixMlyM2zPi-PM3PS6-a-b- qOqClaBrb (Formula I), wherein 4<x<8, 0<y<l, 0<z <1, 0<p<l, 0<q<l, 0<a<2, 0<b<2, 0<6-a- b-q<6, 0<l -p<l , and wherein Ml is at least one element of Group 1 or Group 11 other than H or Li of the periodic table, M2 is at least one element of Group 2 of the periodic table, and M3 is at least one element of Group 14 of the periodic table.

[0041] In some embodiments, Ml is at least one selected from the group consisting of Na, K, Rb, Cs, Cu, Ag, and Au. In some embodiments, M2 is at least one selected from the group consisting of Be, Mg, Ca, Sr, and Ba. In some embodiments, M3 is at least one selected from the group consisting of Si, Ge, Sn, and Pb.

[0042] In some embodiments, b / a has a value in a range from 0 to 20, i.e, 0<b / a<20.

[0043] In some embodiments, the formula of sulfide solid electrolyte in the electrolyte layer, i.e., LixMlyM2zPi-pM3pS6-a-b-qOqClaBrb, does not comprise any of Ml, M2, M3 or O, i.e., y=z=p=q=0, corresponding to a formula of LixPS6-a-bClaBrb.

[0044] In some embodiments, the formula of the sulfide electrolyte comprises at least one element selected from the group consisting of Ml, M2, M3 and O. In some embodiments, theFormula (I) contains one element selected from the group consisting of Ml, M2, M3 and O. In some embodiments, Formula I is selected from the group consisting of:1) LixMlyPSe-a-bClaBrb, where 4<x<8, 0<y<l, 0<a<2, 0<b<2, 0<6-a-b<6;2) LixM2zPS6-a-bClaBrb, where 4<x<8, 0<z<l, 0<a<2, 0<b<2, 0<6-a-b<6;3) LixPi-pM3pS6-a-bClaBrb, where 4<x<8, 0<p<l, 0<a<2, 0<b<2, 0<6-a-b<6, 0<l-p<l; and4) LixPSe-a-b-qOqClaBrb, where 4<x<8, 0<q<l, 0<a<2, 0<b<2, 0<6-a-b-q<6.

[0045] In some embodiments, the Formula (I) contains O and one element selected from the group consisting of Ml, M2, and M3. In some embodiments, the sulfide solid electrolyte has a formula selected from the group consisting of LixMlyPSe-a-b-qOqClaBrb (4<x<8, 0<y< 10<q<l, 0<a<2, 0<b<2, 0<6-a-b-q<6), LixM2zPiS6-a-b-qOqClaBrb (4<x<8, 0<z<l, 0<q<l, 0<a<2, 0<b<2, 0<6-a-b-q<6,), and LixPi-pM3pS6-a-b-qOqClaBrb (4<x<8, 0<p<l, 0<q<l, 0<a<2, 0<b<2, 0<6-a-b-q<6, 0<l-p<l). In one embodiment, the Formula (I) contains O without Ml, M2, or M3. In one embodiment, the formula of the sulfide electrolyte is LixPSe-a-b-qOqClaBrb (4<x<8, 0<q<l, 0<a<2, 0<b<2, 0<6-a-b-q<6). In some embodiments, Ml is at least one element of Group 1 or Group 11 other than H or Li of the periodic table. In some embodiments, Ml is at least one selected from the group consisting of Na, K, Rb, Cs, Cu, Ag, and Au. In some embodiments, M2 is at least one element of Group 2 of the periodic table. In some embodiments, M2 is at least one selected from the group consisting of Be, Mg, Ca, Sr, and Ba. In some embodiments, M3 is at least one element of Group 14 of the periodic table. In some embodiments, M3 is at least one selected from the group consisting of Si, Ge, Sn, and Pb.

[0046] In one embodiment, the sulfide solid electrolyte has a formula of LixPSe-a-b-qOqClaBrb, where 4<x<8, 0<q<l, 0<a<2, 0<b<2, 0<6-a-b-q<6. The incorporation of oxygen into the formula makes such material more stable. In some embodiments, the molar amount of O with q having a value in a range from 0 to 0.1, from 0 to 0.2, from 0 to 0.3, from 0 to 0.4, from 0 to 0.5, from 0 to 0.6, from 0.001 to 0.1, from 0.001 to 0.2, from 0.001 to 0.3, from 0.001 to 0.4, from 0.001 to 0.5, from 0.001 to 0.6, from 0.002 to 0.1, from 0.002 to 0.2, from 0.002 to 0.3,from 0.002 to 0.4, from 0.002 to 0.5, from 0.002 to 0.6, from 0.005 to 0.1, from 0.005 to 0.2, from 0.005 to 0.3, from 0.005 to 0.4, from 0.005 to 0.5, from 0.005 to 0.6, or any and all ranges and subranges therebetween. In one embodiment, the formula is Li5.8PS4.70o.iCli.2.[00471 In some embodiments, the formula is LixPSe-a-b-qOqClaBrb, wherein 4<x<8, 0<q<l, 0<a<2, 0<b<2, 0<6-a-b-q<6. In some embodiments, b / a has a value higher than zero. In some embodiments, b / a has a value in a range from 0 to 3.5. In some embodiments, b / a has a value in a range from 0 to 7. In some embodiments, b / a has a value in a range from 0 to 10, from 0 to 15, or from 0 to 20.

[0048] In some embodiments, when the formula is LixMlyPSe-a-b-qClaBrb, 4<x<8, 0<y<l, 0<a<2, 0<b<2, 0<6-a-b<6, b / a has a value in a range from 0 to 3.5. In some embodiments, b / a has a value in a range from 0 to 7. In some embodiments, b / a has a value in a range from 0 to 10, from 0 to 15, or from 0 to 20. In some embodiments, b / a has a value higher than zero.

[0049] In some embodiments, when the formula is LixM2zPS6-a-bClaBrb, where 4<x<8, 0<z<l, 0<a<2, 0<b<2, 0<6-a-b<6, b / a has a value in a range from 0 to 3.5. In some embodiments, b / a has a value in a range from 0 to 7. In some embodiments, b / a has a value in a range from 0 to 10, from 0 to 15, or from 0 to 20. In some embodiments, b / a has a value higher than zero.

[0050] In one embodiment, when the formula is LixPi-pM3PS6-a-bClaBrb, 4<x<8, 0<p<l, 0<a<2, 0<b<2, 0<6-a-b<6, 0<l-p<l, b / a has a value in a range from 0 to 3.5. In some embodiments, b / a has a value in a range from 0 to 7. In some embodiments, b / a has a value in a range from 0 to 10, from 0 to 15, or from 0 to 20. In some embodiments, b / a has a value higher than zero.

[0051] In some embodiments, the Formula (I) contains O and one element selected from the group consisting of Ml, M2, and M3. In some embodiments, the sulfide solid electrolyte has a formula selected from the group consisting of LixMlyPSe-a-b-qOqClaBrb (4<x<8, 0<y<l,0<q<l, 0<a<2, 0<b<2, 0<6-a-b-q<6), LixM2zPS6-a-b-qOqClaBrb (4<x<8, 0<z<l, 0<q<l, 0<a<2, 0<b<2, 0<6-a-b-q<6,), and LixPi-pM3PS6-a-b-qOqClaBrb (4<x<8, 0<p<l, 0<q<l, 0<a<2, 0<b<2, 0<6-a- b-q<6, 0<l-p<l). In one embodiment, the Formula (I) contains O without Ml, M2, or M3. Inone embodiment, the formula of the sulfide electrolyte is LixPSe-a-b-qOqClaBrb (4<x<8, 0<q<l, 0«2. 0<b<2, 0<6-a-b-q<6). In some embodiments, the molar amount of Br in the formula has a value higher than zero, i.e., b>0.

[0052] In some embodiments, the total molar amount of the halogen in the formula of sulfide electrolyte is no more than 2, i.e., a+b<2. In one embodiment, the total molar amount of the halogen in the formula is no less than 2 and no more than 3, i.e., 2<a+b<3. In one embodiment, the total molar amount of the halogen in the formula is no less than 2 and less than 4, i.e., 2<a+b<4. In one embodiment, the total molar amount of Br and Cl in the formula is no more than 2, i.e., a+b<2, no less than 2 and no more than 3, i.e., 2<a+b<3, or no less than 2 and less than 4, i.e., 2<a+b<4.

[0053] In some embodiments, the sulfide solid electrolyte has a formula selected from the group consisting of:1) LixPSe-a-bClaBrb, where 4<x<8, 0<a<2, 0<b<2, 0<6-a-b<6;2) LixMlyPSe-a-bClaBrb, where 4<x<8, 0<y<l, 0<a<2, 0<b<2, 0<6-a-b<6;3) LixM2zPS6-a-bClaBrb, where 4<x<8, 0<z<l, 0<a<2, 0<b<2, 0<6-a-b<6;4) LixPi-pM3pS6-a-bClaBrb, where 4<x<8, 0<p<l, 0<a<2, 0<b<2, 0<6-a-b<6, 0<l-p<l;5) LixPSe-a-b-qOqClaBrb, where 4<x<8, 0<q<l, 0<a<2, 0<b<2, 0<6-a-b-q<6;6) LixMlyPSe-a-b-qOqClaBrb, where 4<x<8, 0<y<l,0<q<l, 0<a<2, 0<b<2, 0<6-a-b-q<6;7) LixM2zPS6-a-b-qOqClaBrb, where 4<x<8, 0<z<l, 0<q<l, 0<a<2, 0<b<2, 0<6-a-b-q<6;8) LixPi-pM3pS6-a-b-qOqClaBrb, where 4<x<8, 0<p<l, 0<q<l, 0<a<2, 0<b<2, 0<6-a-b-q<6, 0<l-p<l; and9) mixtures thereof.

[0054] In some embodiments, the first electrode is cathode or anode.

[0055] In some embodiments, the anode comprises lithium metal or lithium alloy.

[0056] In some embodiments, the first electrode is cathode.[00571 In some embodiments, the method leads to a yield of at least 80%, at least 85%, at least 90%, at least 91% at least 92%, at least 93%, at least 94% or at least 95%. Yield is the number of cell assemblies that pass a short circuit test divided by the total number of cell assemblies multiplied by 100%.[00581 In some embodiments, the present disclosure provides a battery prepared according to any method disclosed herein.

[0059] In some embodiments, each pre-pressed unit of type A may comprise 2n layers of a first electroactive material, wherein n is an integer equal to or greater than 0. In some embodiments, n can be 0, 2, 4, 6, 8 or 10. When n is 0, it refers to a scenario where the prepressed unit of type A is a top first electrode current collector as shown in Fig. 2.

[0060] As representatively shown in Figs. 1 and 3, a pre-pressed unit of type A includes 2 layers. As shown in Fig. 4, a pre-pressed unit of type A includes 4 layers. In some embodiments, one pre-pressed unit of type A includes:• four first electroactive material layers, i.e., 11-2, 12-2, 13-2 and 14-2,• three first electrode current collectors, i.e., 11-1, 12-1 and 14-1,• four SE layers, i.e., 31, 32, 33 and 34, and• two second electrodes, i.e., 21 and 22, wherein a first second electrode 21 comprises 21-1 as a current collector and a second one comprises a current collector, i.e., 22-1.

[0061] In some embodiments, a pre-pressed unit of type B may comprise 2m layers of a first electroactive material, wherein m is an integer equal to or greater than 1. In some embodiments, m can be 2, 4, 6, 8 or 10. As representatively shown in Fig. 5, a pre-pressed unit of type B includes 2 layers, same as the one shown in Figs. 1 and B. As shown in Fig. 6, a prepressed unit of type B includes 4 layers. In some embodiments, one pre-pressed unit of type B includes:• four first electroactive material layers, i.e., 11-2, 12-2, 13-2 and 14-2, two first electrode current collectors, i.e., 12-1 and 14-1,four SE layers, i.e., 31, 32, 33 and 34, and two second electrodes, i.e., 21 and 22, wherein a first second electrode 21 comprises21-1 as a current collector and a second one comprises a current collector, i.e., 22-1.

[0062] In some embodiments, a cell assembly can be prepared by laminating one pre-pressed unit of type A with 2n layers over one or more pre-pressed units of type B with 2m layers, wherein n is an integer equal to or greater than 0 and m is an integer equal to or greater than 1. In some embodiments, n is the same as or different from m.

[0063] In some embodiments, the method comprises laminating one pre-pressed unit of a first type over one or more pre-pressed units of a second type, wherein the first type and the second type have a different configuration, the bottom of the pre-pressed unit of the first type is functionally complementary to the top of the pre-pressed unit of the second type without structural redundancy at the interface between adjacent units. In some embodiments, when there are multiple pre-pressed units of the second type, the bottom of a first pre-pressed unit of the second type is also functionally complementary to the top of a second pre-pressed unit of the second type without structural redundancy at the interface therebetween. In some embodiments, as shown in Fig. 1, the bottom of the pre-pressed unit of type A (10A) is or configurated as a first electrode current collector (12-1). The bottom of pre-pressed unit of type A (10A) is functionally complementary to the top of the pre-pressed unit of type B (10B) which configurated as a first electroactive material layer (11-2). Furthermore, the bottom of a prepressed unit of type B, also configurated as a first electrode current collector (12-1), is functionally complementary to the top of another pre-pressed unit of type B. When one prepressed unit of type A and one or more pre-pressed units of type B are laminated along the stacking direction, they form a complete battery assembly.

[0064] The configurations of different types of units (or models) and their combination are not limited to those illustrated in the drawings. In some embodiments, the bottom of a pre-pressedunit of the first and second types is a first electrode current collector while the top of a prepressed unit of the second type is a first electroactive material layer.

[0065] In some embodiments, the bottom of a pre-pressed unit of the first and second types is a first electroactive material layer while the top of a pre-pressed unit of the second type is a first electrode current collector. In some scenarios, the pre-assembly further includes one or two current collectors so that the ending layers of the final assembly are a first or second electrode current collector rather than an electroactive material layer or SE layer. In some cases, one pre-pressed unit of the first type may have p layers of the first electroactive material layer, wherein p is an integer equal to or greater than 0. In some cases, one pre-pressed unit of the second type may have q layers of the first electroactive material layer, wherein q is an integer equal to or greater than 0.

[0066] In some embodiments, the first electrode is a cathode or an anode.

[0067] In some embodiments, the battery is an anode-less or anode-free battery, wherein an anode active material layer is formed after the first charge. In some embodiments, the bottom of a pre-pressed unit of the first and second types is an anode current collector while the top of a pre-pressed unit of the second type is an SE layer. In some embodiments, the bottom of a prepressed unit of the first and second types is an SE layer while the top of a pre-pressed unit of the second type is an anode current collector.

[0068] In some embodiments, a pre-pressed unit of a first type is over one or more pre-pressed units of a second type, wherein the first type and the second type have a different configuration. On the one hand, the bottom of the pre-pressed unit of the first type is functionally complementary to the top of the pre-pressed unit of the second type without structural redundancy between adjacent units. On the other hand, the bottom of a first pre-pressed unit of the second type is functionally complementary to the top of a second pre-pressed unit of the second type without structural redundancy between adjacent units, wherein the second prepressed unit is beneath the first pre-pressed unit.

[0069] In some embodiments, a pre-pressed unit of type A, as a typical first type, may be further divided into two or more components. For example, a pre-pressed unit of type A may be divided into a top first electrode current collector (11-1) and a pre-pressed unit of type B (as a second type). As shown in Fig. 2, a cell assembly can be prepared by laminating one top first electrode current collector (11-1) over one or more pre-pressed units of type B as a typical second type. The bottom of the pre-pressed unit of type A is functionally complementary to the top of the pre-pressed unit of type B with no structural redundancy. The bottom of the prepressed unit of type B is functionally complementary to the top of the pre-pressed unit of type B. Structural redundancy refers to two components in two subunits and those two components after lamination do not introduce new functions other than that in separate subunits, i.e., before laminating or combining subunits into a larger assembly. Structural redundancy may result in lower energy density if the redundant component has less or no contribution to energy density.

[0070] In some embodiments, a pre-pressed unit of type A may be further divided into two or more components. For example, a pre-pressed unit of type A may be divided into a top first electrode current collector (11-1) and a pre-pressed unit of type B. In some embodiments, a cell assembly (100) is prepared by laminating a number of first electrode current collectors with one or more pre-pressed units of type C as exemplarily shown in Fig. 7.

[0071] In some embodiments, a pre-pressed unit of type B is further divided into a bottom first electrode current collector (12-1) and a pre-pressed unit of type C. For example, an assembly (100) may be prepared by stacking a top first electrode current collector (11-1), one or more pre-pressed units of type C and one or more bottom first electrode current collector (12-1) as shown in Fig. 7.

[0072] In some embodiments, an assembly may be prepared by stacking one pre-pressed unit of type A, one or more pre-pressed units of type C, and one or more bottom electrode current collectors.[00731 In some embodiments, an assembly may be prepared by stacking one pre-pressed unit of type A, one or more pre-pressed units of type B, one or more pre-pressed units of type C, and one or more bottom electrode current collectors.

[0074] Although the disclosed teachings have been described with reference to various applications, methods, compounds, compositions, and materials, it will be appreciated that various changes and modifications to them may be made without departing from the teachings herein. The following examples are provided to better illustrate the disclosed teachings and are not intended to limit the scope of the teachings presented herein. As described herein, when a part such as a layer, unit, component, etc. is described as "on", "above" or “over” another, this includes both the scenario where the part is directly on top of another part and the scenario where a third part is located between these two parts. Terms such as first and second may be used to describe various components, but the components should not be limited by the terms. Terms such as top and bottom are used to distinguish one component from another in view of their relative locations, rather than limiting to a fixed configuration wherein a top component is on the top of a bottom component. For example, a top first electrode current collector should be interpreted as a first electrode current collector placed above or below another component on the left or right side of another component.

[0075] While the present teachings have been described in terms of these exemplary embodiments, the skilled artisan will readily understand that numerous variations and modifications of these exemplary embodiments are possible without undue experimentation. All such variations and modifications are within the scope of the teachings of this disclosure.ExamplesPreparation of cell assemblies

[0076] A pre-pressed unit of type A was prepared by stacking a top first electrode current collector, a top first electroactive material layer, a top solid electrolyte layer, a second electrode current collector, a bottom solid electrolyte layer, a bottom first electroactive material layerand a bottom first electrode current collector in the order into a bag, conducting an isostatic pressing, and removing the stacked unit from the bag. A pre-pressed unit of type B was similarly prepared except that it did not include the top first electrode current collector.

[0077] A cell assembly was prepared by laminating one pre-pressed unit of type A over one or more pre-pressed units of type B followed by a pressurization on a vacuuming machine to reach a vacuum percentage of at least 99.8%. A cell assembly with a capacity of 4Ah was assembled with one pre-pressed unit of type A and one pre-pressed unit of type B, wherein each unit has a capacity of 2Ah. A cell assembly with a capacity of 8 Ah was assembled with one pre-pressed unit of type A and three pre-pressed units of type B. As for comparative examples, the cell assemblies were prepared by using a one-step WIP, wherein all components were laminated without formation of units. The yields are summarized in Table 1. Yield is determined by the number of cell assemblies that pass a short-circuit test divided by all the cell assemblies multiplied by 100%.

[0078] It shows that the comparative method could lead to a yield of -77% and -66% for an assembly with a capacity of 4Ah and 8Ah, respectively. As the capacity of an assembly increases, it requires more layers for the laminations, and it may lead to a lower yield. In contrast, the present method can lead to a constant yield of -95% for these two cell assemblies. Table 1 Yields of assemblies of all solid-state battery (AS SB)Aspects

[0079] In a first aspect of the present disclosure, a method of preparing an assembly of a battery is disclosed, wherein the battery comprises multiple first electrodes, multiple second electrodes,and multiple solid electrolyte (SE) layers each SE layer disposed between a first electrode and a second electrode. The method comprises:• laminating one pre-pressed unit of a first type over one or more pre-pressed units of a second type, forming a pre-assembly, wherein the first type and the second type have a different configuration, the bottom of the pre-pressed unit of the first type is functionally complementary to the top of the pre-pressed unit of the second type without structural redundancy; and• pressurizing the pre-assembly, thereby obtaining an assembly.

[0080] In a second aspect according to the first aspect, the pre-assembly comprises a first prepressed unit and a second pre-pressed unit of the second type, and the bottom of the first prepressed unit of the second type is functionally complementary to the top of the second prepressed unit of the second type without structural redundancy.

[0081] In a third aspect according to the first aspect, the pre-pressed unit of the first type is a pre-pressed unit of type A prepared by compressing a unit of type A by an isostatic compression, the unit of type A comprises a top first electrode current collector, a top first electroactive material layer, a top solid electrolyte layer, optionally a top second electroactive material layer, a second electrode current collector, optionally a bottom second electroactive material layer, a bottom solid electrolyte layer, a bottom first electroactive material layer and a bottom first electrode current collector in the order, each pre-pressed unit of the second type is a pre-pressed unit of type B prepared by compressing a unit of type B by an isostatic compression, each unit of type B comprises a top first electroactive material layer, a top solid electrolyte layer, optionally a top second electroactive material layer, a second electrode current collector, optionally a bottom second electroactive material layer, a bottom solid electrolyte layer, a bottom first electroactive material layer and a bottom first electrode current collector in the order, and the bottom first electrode current collector in the pre-pressed unit of type A isadjacent to the top first electroactive material layer in one of the one or more pre-pressed units of type B.

[0082] In a fourth aspect according to the first aspect, the pre-pressed unit of the first type is a first electrode current collector, each pre-pressed unit of the second type is a pre-pressed unit of type B prepared by compressing a unit of type B by an isostatic compression, wherein each unit of type B comprises a top first electroactive material layer, a top solid electrolyte layer, optionally a top second electroactive material layer, a second electrode current collector, optionally a bottom second electroactive material layer, a bottom solid electrolyte layer, a bottom first electroactive material layer and a bottom first electrode current collector in the order, and the top first electrode current collector of the first type is adjacent to the top first electroactive material layer in one of the one or more pre-pressed units of type B.

[0083] In a fifth aspect according to the first aspect, the first electrode is cathode and the second electrode is anode.

[0084] In a sixth aspect according to the fifth aspect, the anode comprises lithium metal or lithium alloy.

[0085] In a seventh aspect according to the first aspect, the battery is an all solid-state battery (ASSB) comprising a polymer electrolyte, an inorganic oxide electrolyte or an inorganic sulfide electrolyte. In some embodiments, the inorganic sulfide electrolyte has a formula (I) LixMlyM2zPi-pM3pS6-a-b-qOqClaBrb (Formula I), wherein 4<x<8, 0<y<l, 0<z <1, 0<p<l, 0<q<l, 0<a<2, 0<b<2, 0<6-a-b-q<6, 0< 1 -p<l , wherein Ml is at least one element of Group 1 or Group 11 other than H or Li of the periodic table, M2 is at least one element of Group 2 of the periodic table, and M3 is at least one element of Group 14 of the periodic table.

[0086] In an eighth aspect according to the first aspect, the isostatic compression for each unit of the first type and the second type is independently conducted at a temperature in a range from 0 °C to 150 °C and at a pressure normal to the surface of the first electroactive material layer in a range from 10 MPa to 1000 MPa. In some embodiments, the isostatic compressionfor each unit of the first type and the second type is independently conducted prior to, concurrently with, or after heating to an elevated temperature in a range from 20 °C to 150 °C.

[0087] In a nineth aspect according to the first aspect, the first electrodes are substantially parallel to the second electrodes.

[0088] In a tenth aspect according to the first aspect, the pre-assembly is pressurized by placing the pre-assembly into a vacuuming bag followed by vacuuming the vacuuming bag to a preset vacuum percentage.

[0089] In an eleventh aspect according to the tenth aspect, the preset vacuum percentage is at least 99.0%.

[0090] In a twelfth aspect according to any preceding aspect, the method leads to a yield of at least 80%, wherein the yield is the number of cell assemblies that pass a short circuit test divided by the total number of cell assemblies multiplied by 100%.

[0091] In a thirteenth aspect of the present disclosure, the method comprises: a) having a pre-pressed unit of type A which is compressed by an isostatic compression, wherein the unit of type A comprises a top first electrode current collector, a top first electroactive material layer, a top solid electrolyte layer, optionally a top second electroactive material layer, a second electrode current collector, optionally a bottom second electroactive material layer, a bottom solid electrolyte layer, a bottom first electroactive material layer and a bottom first electrode current collector in the order, b) having one or more pre-pressed units of type B, each unit of type B compressed by an isostatic compression on each of one or more units of type B, wherein each unit of type B comprises a top first electroactive material layer, a top solid electrolyte layer, optionally a top second electroactive material layer, a second electrode current collector, optionally a bottom second electroactive material layer, a bottom solid electrolyte layer, a bottom first electroactive material layer and a bottom first electrode current collector in the order,c) laminating one pre-pressed unit of type A over the one or more pre-pressed units of type B into a pre-assembly, wherein the bottom first electrode current collector in the pre-pressed unit of type A is adjacent to the top first electroactive material layer in one of the one or more pre-pressed units of type B, and d) pressurizing the pre-assembly, thereby obtaining an assembly.

[0092] In a fourteenth aspect according to the thirteenth aspect, the first electrode is cathode and the second electrode is anode. In some embodiments, the first electrodes are substantially parallel to the second electrodes. In some embodiments, the pre-assembly is pressurized by placing the pre-assembly into a vacuuming bag followed by vacuuming the vacuuming bag to a preset vacuum percentage. In some embodiments, the preset vacuum percentage is at least 99.0%.

[0093] In a fifteenth aspect of the present disclosure, the method comprises: a) having a top first electrode current collector, b) having one or more pre-pressed units of type B, each unit of type B compressed by an isostatic compression on each of one or more units of type B, wherein each unit of type B comprises a top first electroactive material layer, a top solid electrolyte layer, optionally a top second electroactive material layer, a second electrode current collector, optionally a bottom second electroactive material layer, a bottom solid electrolyte layer, a bottom first electroactive material layer and a bottom first electrode current collector in the order, c) laminating the top first electrode current collector over the one of the one or more pre-pressed units of type B into a pre-assembly, wherein the top first electrode current collector is adjacent to the top first electroactive material layer in the prepressed unit of type B, and d) pressurizing the pre-assembly, thereby obtaining an assembly.[0094| In some embodiments, the first electrode is a cathode and the second electrode is an anode. In some embodiments, the anode comprises lithium metal or lithium alloy. In some embodiments, the isostatic compression for each unit of type A and type B is independently conducted at a temperature in a range from 0 °C to 150 °C and at a pressure normal to the surface of the first electroactive material layer in a range from 10 MPa to 1000 MPa. In some embodiments, the isostatic compression for each unit of type B is conducted prior to, concurrently with or after heating to an elevated temperature in a range from 20 °C to 150 °C.

[0095] In some embodiments, the present disclosure provides a battery prepared according to any preceding aspect.

[0096] While this specification contains many specific implementation details, these should not be construed as limitations on the scope of any invention or of what may be claimed, but rather as descriptions of features that may be specific to particular embodiments of particular inventions. Certain features that are described in this specification in the context of separate embodiments can also be implemented in combination in a single embodiment. Conversely, various features that are described in the context of a single embodiment can also be implemented in multiple embodiments separately or in any suitable subcombination. Moreover, although features may be described above as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination can in some cases be excised from the combination, and the claimed combination may be directed to a subcombination or variation of a subcombination.

[0097] All transitional phrases such as “comprising,” “including,” “carrying,” “having,” “containing,” “involving,” “holding,” “composed of,” and the like are to be understood to be open-ended, i.e., to mean including but not limited to. Only the transitional phrases “consisting of’ and “consisting essentially of’ shall be closed or semi-closed transitional phrases, respectively.[00981 Various embodiments of the features of this disclosure are described herein. However, it should be understood that such embodiments are provided merely by way of example, and numerous variations, changes, and substitutions can occur to those skilled in the art without departing from the scope of this disclosure. It should also be understood that various alternative to the specific embodiments described herein are also within the scope of this disclosure.

Claims

What is claimed is:

1. A method of preparing an assembly of a battery comprising multiple first electrodes, multiple second electrodes, and multiple solid electrolyte (SE) layers each SE layer disposed between a first electrode and a second electrode, the method comprising:• laminating one pre-pressed unit of a first type over one or more pre-pressed units of a second type, forming a pre-assembly, wherein the first type and the second type have a different configuration, the bottom of the pre-pressed unit of the first type is functionally complementary to the top of the pre-pressed unit of the second type without structural redundancy; and• pressurizing the pre-assembly, thereby obtaining an assembly,2. The method of claim 1, wherein the pre-assembly comprises a first pre-pressed unit and a second pre-pressed unit of the second type, and the bottom of the first pre-pressed unit of the second type is functionally complementary to the top of the second pre-pressed unit of the second type without structural redundancy.

3. The method of claim 1, wherein the pre-pressed unit of the first type is a pre-pressed unit of type A prepared by compressing a unit of type A by an isostatic compression, the unit of type A comprises a top first electrode current collector, a top first electroactive material layer, a top solid electrolyte layer, optionally a top second electroactive material layer, a second electrode current collector, optionally a bottom second electroactive material layer, a bottom solid electrolyte layer, a bottom first electroactive material layer and a bottom first electrode current collector in the order, each pre-pressed unit of the second type is a pre-pressed unit of type B prepared by compressing a unit of type B by an isostatic compression, each unit of type B comprises a top first electroactive material layer, a top solid electrolyte layer, optionally a top secondelectroactive material layer, a second electrode current collector, optionally a bottom second electroactive material layer, a bottom solid electrolyte layer, a bottom first electroactive material layer and a bottom first electrode current collector in the order, and the bottom first electrode current collector in the pre-pressed unit of type A is adjacent to the top first electroactive material layer in one of the one or more pre-pressed units of type B.

4. The method of claim 1, wherein the pre-pressed unit of the first type is a first electrode current collector, each pre-pressed unit of the second type is a pre-pressed unit of type B prepared by compressing a unit of type B by an isostatic compression, wherein each unit of type B comprises a top first electroactive material layer, a top solid electrolyte layer, optionally a top second electroactive material layer, a second electrode current collector, optionally a bottom second electroactive material layer, a bottom solid electrolyte layer, a bottom first electroactive material layer and a bottom first electrode current collector in the order, and the top first electrode current collector of the first type is adjacent to the top first electroactive material layer in one of the one or more pre-pressed units of type B.

5. The method of claim 1, wherein the first electrode is a cathode and the second electrode is an anode.

6. The method of claim 5, wherein the anode comprises lithium metal or lithium alloy.

7. The method of claim 1, wherein the battery is an all solid-state battery (ASSB) comprising a polymer electrolyte, an inorganic oxide electrolyte or an inorganic sulfide electrolyte.

8. The method of claim 1, wherein the isostatic compression for each unit of the first type and the second type is independently conducted at a temperature in a range from 0°C to 150 °C and at a pressure normal to the surface of the first electroactive material layer in a range from 10 MPa to 1000 MPa, and the isostatic compression for each unit of the first type and the second type is independently conducted prior to, concurrently with, or after heating to an elevated temperature in a range from 20 °C to 150 °C.

9. The method of claim 1, wherein the first electrodes are substantially parallel to the second electrodes.

10. The method of claim 1, wherein the pre-assembly is pressurized by placing the preassembly into a vacuuming bag followed by vacuuming the vacuuming bag to a preset vacuum percentage.

11. The method of claim 10, wherein the preset vacuum percentage is at least 99.0%.

12. The method of any preceding claim, wherein the method leads to a yield of at least 80%, wherein the yield is the number of cell assemblies that pass a short circuit test divided by the total number of cell assemblies multiplied by 100%.

13. A method of preparing an assembly of a battery comprising multiple first electrodes, multiple second electrodes, and multiple solid electrolyte (SE) layers each SE layer disposed between a first electrode and a second electrode, the method comprising: a) having a pre-pressed unit of type A which is compressed by an isostatic compression, wherein the unit of type A comprises a top first electrode current collector, a top first electroactive material layer, a top solid electrolyte layer, optionally a top secondelectroactive material layer, a second electrode current collector, optionally a bottom second electroactive material layer, a bottom solid electrolyte layer, a bottom first electroactive material layer and a bottom first electrode current collector in the order, b) having one or more pre-pressed units of type B, each unit of type B compressed by an isostatic compression on each of one or more units of type B, wherein each unit of type B comprises a top first electroactive material layer, a top solid electrolyte layer, optionally a top second electroactive material layer, a second electrode current collector, optionally a bottom second electroactive material layer, a bottom solid electrolyte layer, a bottom first electroactive material layer and a bottom first electrode current collector in the order, c) laminating one pre-pressed unit of type A over the one or more pre-pressed units of type B into a pre-assembly, wherein the bottom first electrode current collector in the pre-pressed unit of type A is adjacent to the top first electroactive material layer in one of the one or more pre-pressed units of type B, and d) pressurizing the pre-assembly, thereby obtaining an assembly.

14. The method of claim 13, wherein the first electrode is a cathode and the second electrode is an anode.

15. A method of preparing an assembly of a battery comprising multiple first electrodes, multiple second electrodes, and multiple solid electrolyte each disposed between a first electrode and a second electrode, the method comprising: a) having a top first electrode current collector, b) having one or more pre-pressed units of type B, each unit of type B compressed by an isostatic compression on each of one or more units of type B, wherein each unit of type B comprises a top first electroactive material layer, a top solid electrolyte layer,optionally a top second electroactive material layer, a second electrode current collector, optionally a bottom second electroactive material layer, a bottom solid electrolyte layer, a bottom first electroactive material layer and a bottom first electrode current collector in the order, c) laminating the top first electrode current collector over the one of the one or more pre-pressed units of type B into a pre-assembly, wherein the top first electrode current collector is adjacent to the top first electroactive material layer in the prepressed unit of type B, and d) pressurizing the pre-assembly, thereby obtaining an assembly.

Images