In SITU coupling of components with electrochemical cell assemblies

Abstract

The present inventions relate to methods, devices, systems, apparatuses, controllers, software, and designs associated with in situ coupling of components external to a cell assembly, while the cell assembly contacts the components, the coupling being at a temperature higher than a temperature threshold of the cell assembly, and the cell assembly being unharmed by the coupling.

Description

Atorney Docket No. 000456-0108-WO1 (ENX-0154.WO)IN SITU COUPLING OF COMPONENTS WITH ELECTROCHEMICAL CELL ASSEMBLIESPRIORITY APPLICATIONS

[0001] This application claims priority to U.S. Provisional Patent Application No. 63 / 682,630, filed on August 13, 2024, which is incorporated herein by reference in its entirety.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 batteries, to energy manipulation devices employing such structures, and to methods for manufacturing such structures and energy manipulation devices. In an example, the present invention relates to methods and structures such as electrode assemblies for use in energy storage devices such as secondary batteries, to energy storage devices employing such structures, and to methods for manufacturing such structures and energy 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. 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, and / or magnesium ions, travel between a cathode structure and an anode structure through an electrolyte within each cell. In such batteries, the anode structure and cathode structure are separated by a separator structure during assembly of the battery and during battery operation. In an example, anode and cathode current collectors pool electric current from the respective active electrochemical electrodes and at least in part enable transfer of the current to the environment outside the battery.

[0004] There are a number of shortcomings related to such energy manipulation devices and / or the process of making these devices. The electrochemical cell assembly can be disposed in a casing that includes several sections requiring physical (e.g., irreversible) coupling with one another. The physical coupling (e.g., joining, or connecting) should be configured such that it remains in-tact during the prescribed operation of the battery, e.g., during its prescribed lifetime and / or prescribed operative conditions. The physical coupling can be effectuated using a phase change operation in the immediately adjacent casing sections. The physical coupling can be effectuated using a metallurgical process in theAtorney Docket No. 000456-0108-WO1 (ENX-0154.WO) immediately adjacent casing sections. The physical coupling can be effectuated using fusing of immediately adjacent casing sections. The fusing process can comprise melting, sintering, or at least partially liquefying. The fusing process can comprise welding, e.g., fusion welding. The coupling may include welding. The welding may comprise laser welding, plasma arc welding, gas welding, shielded metal arc welding (aka stick welding), or any combination thereof. The welding may include fusion welding and / or solid-state welding. The physical coupling can be effectuated using welding of immediately adjacent casing sections. The immediately adjacent sections can be contacting one another. The casing can include a constraint system configured to curb dimensional alteration of the cell assembly during use that entails volumetric change of the cell assembly disposed in the constraint system’s interior. The physical coupling of the constraint sections should be configured to curb volumetric alteration of the cell assembly during its use such as cycling between charged and discharged state, buffering, passivation layer formation, or any combination thereof. The physical coupling process should not initiate, or cause, harm (e.g., to the cell assembly) such as by initiating a thermal runaway reaction. The harm may comprise a harmful (e.g., catastrophic) event to the battery, to personnel, to the ambient environment external to the battery such as to the facility in which the battery is disposed, or any combination thereof. The physical coupling may be designed to reduce displacement, separation, and / or deformation, of internal components relative to the casing (e.g., including the constraint system), while maintaining geometric alignment of the constraint system with respect to the cell assembly. There are a number of shortcomings related to the energy manipulation devices (e.g., secondary batteries) and the process of making the energy manipulation devices. For example, during the manufacturing of the energy manipulation devices using a constraint system, a welding process takes place to secure the constraint with the rest of the enclosure. The welding may include the use of laser welding. However, laser welding may (e.g., often) result in thermal damage to the underlying components of the energy manipulation device such as the secondary battery. Accordingly, systems and methods are disclosed herein for sequencing techniques that reduce or eliminate thermal damage during coupling (e.g., fusing) of constraint portions such as of a secondary battery constraint. In some examples, systems and methods are disclosed herein for laser sequencing techniques that reduce, or eliminate, thermal damage during laser welding of a secondary battery constraint system.

[0005] In some embodiments, there is a requirement for heat management in fusing (e.g., welding) the physical coupling of immediately adjacent sections of the casing of the battery such as of the constraint system. There is a requirement for a coupling method that enables structural integration of casing components (e.g., of the constraint system components), while maintaining thermal compatibility with the cell assembly.Atorney Docket No. 000456-0108-WO1 (ENX-0154.WO)

[0006] While the disclosure describes the coupling being done by welding, any other coupling methodology can be employed (e.g., sintering), as applicable.TECHNICAL FIELD OF INVENTION

[0007] The present disclosure relates to structural integration of a casing (e.g., including a constraint system) for electrochemical cell assemblies, particularly the present disclosure relates to coupling strategies of components of a casing (e.g., including a constraint system) using thermally controlled coupling (e.g., welding) methods.SUMMARY

[0008] In some aspects, the present disclosure resolves one or more of the aforementioned hardships and / or shortcomings. In some embodiments, the present disclosure provides solutions to curtail the aforementioned hardships and / or shortcomings. The solutions include method(s), device(s), apparatus(es), system(s), and / or design(s). In some aspects, the present inventions relate to method(s), device(s), apparatus(es), system(s), and design(s), utilized for a battery comprising cell(s). Methods, apparatuses, devices, program instructions, and structures, are disclosed herein for physically coupling sections of a casing (e.g., a constraint system) of an electrochemical cell assembly through coupling (e.g., welding). The coupling can be configured to curb volumetric alteration of the cell assembly beyond a threshold, during use and to enhance thermal stability during the welding process. The threshold may comprise volumetric tolerances requested by the manufacturer, customer, jurisdictional standards, and / or industry standards.

[0009] In some aspects, disclosed herein are generate a succession of fusion (e.g., welding) spots in which two welding spots in the succession are generated in a non-successive manner. In some aspects, disclosed herein are generate a succession of single files of fusion (e.g., welding) spots in which two single files of the welding spots in the succession of single files are generated in a non-successive manner, e.g., the single files are arranged in a succession of single files, and that succession of single files is not successively made. The coupling may comprise an irreversible coupling such as disclosed herein. The succession may comprise a single file of welding spots, or several files of welding spots, e.g., two spatially immediately adjacent and / or parallel single files. Two immediately adjacent single files of coupling spots exclude a single file disposed therebetween. The succession of welding spots is disposed on a region in which a first planar (e.g., substantially flat) section of the casing overlaps a second planar (e.g., substantially flat) section of the casing, in a direction normal to the (planar) welding direction. By adjusting the welding pattern and speed, the heat generated by the welding is distributed more evenly as compared to a situation in which the succession of welding (e.g., spots and / or single files) would be successively made, hindering (e.g., measurably and / or substantially preventing) damage to the components of the cell assembly such as damage to the separator layer, and the electrode active material type(s).Atorney Docket No. 000456-0108-WO1 (ENX-0154.WO)

[0010] In another aspect, a secondary battery comprising a battery enclosure, and an electrode assembly and an electrolyte within the battery enclosure, wherein: (a) 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, and (b) the battery enclosure comprises a constraint, wherein the constraint is laser welded using a laser welding sequence, wherein the laser welding sequence reduces (e.g., prevents) thermal damage to the battery enclosure.

[0011] In another aspect, a method of laser welding a constraint of a secondary battery, the method comprises: 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; producing a secondary battery having a battery enclosure including a constraint (e.g., constraint system), and the electrode assembly and an electrolyte within the battery enclosure; and laser welding the constraint using a laser welding sequence, wherein the laser welding sequence prevents thermal damage to the battery enclosure.

[0012] In another aspect, a device for energy manipulation of an electrochemical cell assembly, the device comprises: a cell assembly being the electrochemical cell assembly comprising an electrode separated from a counter electrode by a gap, the cell assembly comprising at least one temperature susceptible material above a temperature threshold; a first component of a constraint system contacting the cell assembly; and a second component of a constraint system contacting the cell assembly, the second component being coupled with the first component using couplings generated at a coupling temperature above the temperature threshold, the coupling temperature resulting in harm to a prescribed operation of the device, the second component being coupled with the first component in a manner indicative of the cell assembly being in contact with the first component and / or second component during the coupling, the device being (e.g., substantially, detectably and / or measurably) unharmed by the coupling. In some embodiments, the thickness of the first component and / or second component is at most about 50 micrometers (pm), 100 pm, or 150 pm. In some embodiments, the first component is thicker than the second component. In some embodiments, the first component is thicker than the second component. In some embodiments, the first component has a thickness of the second component. In some embodiments, the cell assembly comprises at least about 50-, 100-, or 150-unit cells. In some embodiments, the unit cells are horizontally stacked along a stacking axis. In some embodiments, the cell assembly forms a prismatic arrangement of the unit cells. In some embodiments, the stacking axis is parallel to a face type of the prismatic arrangement having a largest surface area among face types of the prism. In some embodiments, the prism is a rectangular prism. In some embodiments, the couplings are indicative of being generated by at least one energy beam having (a) a low power of at most about 10 Watts or 100 wattsAtorney Docket No. 000456-0108-WO1 (ENX-0154.WO) and / or (b) footprint having a small fundamental length scale of at most about 200 micrometers or 500 micrometers. In some embodiments, the at least one energy beam comprises a laser beam. In some embodiments, the couplings are spaced apart on a single file of couplings along a lateral axis of the first component at an intra-file distance, wherein the couplings comprise spots arranged in single files parallel to each other; wherein a first set of the single files that are successive are distanced from each other by a first inter-file distance, the intra-file distance being larger than the first inter-file distance. In some embodiments, a second set of the single files that are successive are distanced from each other by a second inter-file distance, the second inter-file distance being larger than the intra-file distance and larger than the first inter-file distance. In some embodiments, the single files are (e.g., substantially) of the same length. In some embodiments, the single files comprise the same number of couplings. In some embodiments, the couplings of at least two files in the single files, are arranged parallel to each other. In some embodiments, the couplings of at least two files in the single files, are arranged in a non-staggered matter with respect to each other. In some embodiments, the couplings in the single files are arranged on axes perpendicular to a lateral direction. In some embodiments, the couplings are configured to withstand pressure variations of at least about 100 pounds per square inch (psi), 200psi, 450psi, or 1000psi; wherein the couplings are configured to withstand pressure variations repeatedly over the prescribed operation of the device. In some embodiments, the device is a rechargeable battery comprising the cell assembly. In some embodiments, the electrode includes active material comprising silicon. In some embodiments, the silicon is at least about 30%, 40%, or 60%, or 80% weight by weight. In some embodiments, the at least one temperature susceptible material is devoid of observable, measurable and / or substantial defects to an extent that the harm results during a prescribed lifetime of the device in the prescribed operation of the device. In some embodiments, the prescribed operation of the device comprises charge carrier buffering, passivating the electrode, passivation the counter electrode, chemical interaction of the cell assembly with an electrolyte mixture, cycles electrical charge and discharge of the cell assembly, storage, or any combination thereof. In some embodiments, the device is a rechargeable battery comprising the cell assembly. In some embodiments, the electrode includes active material comprising silicon. In some embodiments, the silicon is at least about 30%, 40%, or 60%, or 80% weight by weight, wherein the manner indicative of the cell assembly being in contact with the first component and / or second component during the coupling comprise (a) the first component being an endplate integrated with the cell assembly, (b) the second component comprising an adhesive adhering to the cell assembly, (c) the second component comprising opposing rigid bodies enclosing the cell assembly. In some embodiments, the first component comprises opposing endplates each disposed at a distal end of the cell assembly, and each coupled toAtorney Docket No. 000456-0108-WO1 (ENX-0154.WO) the second component such that the cell assembly is disposed in an interior space of the constraint system generated by coupling the first component to the second component. In some embodiments, the adhesive is coupled to a ceramic coating of the cell assembly that remains in-tact in the device during the prescribed operation. In some embodiments, the opposing rigid bodies enclosing the cell assembly coupled with the first component cause the cell assembly to become confined (e.g., entrapped) within the cell assembly. In some embodiments, a prescribed operation of the device comprises cycling between charge and discharged state of the cell assembly. In some embodiments, the cycling comprises at least about 300 cycles, 500 cycles, 800 cycles, 1000 cycles, or 1200 cycles. In some embodiments, the couplings are metallurgical. In some embodiments, the couplings are indicative of being generated using welding and / or fusing. In some embodiments, the gap comprises a separator configured to allow separation of electrical change, and transfer of charge carriers therethrough, the at least one temperature susceptible material comprising the separator. In some embodiments, the separator comprising a polymer, a resin, any plurality of types thereof, or any combination thereof. In some embodiments, the separator comprises a ceramic. In some embodiments, the harm is optically visible using a naked human eye and / or optical microscopy. In some embodiments, the harm comprises melting, liquefication, cracking, warping, bending, or otherwise deforming the separator. In some embodiments, the cell assembly comprises spacer members configured to support an electrode current collector that is part of the electrode, the at least one temperature susceptible material comprising the spacer members. In some embodiments, the spacer members comprising a polymer, a resin, any plurality of types thereof, or any combination thereof. In some embodiments, the harm comprises melting, liquefication, cracking, warping, bending, or otherwise deforming a separator, the at least one temperature susceptible material comprising the separator. In some embodiments, the electrode and the counter electrode are stacked along a stacking axis, the first component comprising an endplate disposed at a distal end of the cell assembly, the endplate being stacked along the stacking axis. In some embodiments, the endplate comprises an elemental metal, a metal alloy, any plurality of type thereof, or any combination thereof. In some embodiments, the electrode and the counter electrode are stacked along a stacking axis; wherein the second component comprises an rigid portion having a main body and a flange at a distal end of the main body, the main body being disposed parallel to the stacking axis, and the flange being disposed perpendicular to the stacking axis. In some embodiments, the rigid portion comprises an elemental metal, a metal alloy, any plurality of type thereof, or any combination thereof. In some embodiments, the main body is configured to allow charge carriers to traverse therethrough, and maintaining dimensionality of the device within tolerances during charge and discharge cycles of the cell assembly. In some embodiments, the electrode comprisesAtorney Docket No. 000456-0108-WO1 (ENX-0154.WO) silicon. In some embodiments, a content of the silicon of the electrode is at least about 40% weight by weight. In some embodiments, the main body is coupled with the cell assembly using an adhesive structure indicative of being applied onto the main body prior to generation of the couplings. In some embodiments, the adhesive structure comprises a polymer, a resin, a plurality of types thereof, or any combination thereof. In some embodiments, the temperature threshold is a first temperature threshold, the constraint system comprises one or more temperature susceptible materials above a second temperature threshold, the coupling temperature being above the temperature threshold, the coupling temperature resulting in harm to the one or more temperature susceptible materials, the one or more temperature susceptible materials comprising the adhesive structure. In some embodiments, the main body comprises a coating configured to hinder deposition of reduced form of charge carriers thereof during operation of the device, the one or more temperature susceptible materials comprising the coating. In some embodiments, the energy manipulation device comprises a rechargeable battery. In some embodiments, the energy manipulation device comprises a lithium-ion battery. In some embodiments, the electrode comprises silicon. In some embodiments, a content of the silicon of the electrode is at least about 40% weight by weight. In some embodiments, the harm includes harm to the at least one temperature susceptible material of the cell assembly. In some embodiments, the temperature threshold is a first temperature threshold; and wherein the constraint system comprises one or more temperature susceptible materials above a second temperature threshold, the coupling temperature being above the temperature threshold, the coupling temperature resulting in harm to the one or more temperature susceptible materials. In some embodiments, the couplings are irreversible under a prescribed operating conditions of the device. In some embodiments, the prescribed operating conditions of the device abide by jurisdictional standards and / or industry standards.

[0013] In another aspect, a method comprises: (a) providing any of the above devices; and (b) manufacturing, testing, buffering, storing, transporting, and / or using the device for the energy manipulation. In some embodiments, the use of the device of the energy manipulation comprises cycling the cell assembly between electrical charged and discharge states.

[0014] In another aspect, an apparatus for using any of the above devices, the apparatus comprises: at least one controller configured for (a) operatively couple with at least one mechanism and with the device; and (b) executing, or directing the at least one mechanism to execute, one or more operations associated with use of the device. In some embodiments, the at least one controller is configured to operatively couple with a power source and / or with a communication platform. In some embodiments, one or more of the at least one mechanism is of the device.Atorney Docket No. 000456-0108-WO1 (ENX-0154.WO)

[0015] In another aspect, one or more non-transitory computer readable media comprise program instruction physically inscribed thereon, the program instructions, when read by one or more processors, are configured to (I) execute, or direct execution of, one or more operations associated with use of any of the above devices, and (II) the one or more operations comprising directing at least one component to execute the one or more operations, the one or more processors being configured to operatively couple with the at least one component. In some embodiments, one or more of the at least one component is of the device.

[0016] In another aspect, an apparatus for fabricating any of the above devices, the apparatus comprises: at least one controller configured for (a) operatively coupling with at least one mechanism; and (b) executing, or directing the at least one mechanism to execute, one or more operations associated with fabrication of the device. In some embodiments, the at least one controller is configured to operatively couple with a power source and / or with a communication platform.

[0017] In another aspect, one or more non-transitory computer readable media comprise program instruction physically inscribed thereon, the program instructions, when read by one or more processors, are configured to (I) execute, or direct execution of, one or more operations associated with fabrication of any of the above devices, and (II) the one or more operations comprising directing at least one component to execute the one or more operations, the one or more processors being configured to operatively coupe with the at least one component.

[0018] In another aspect, a method of fabricating any of the above devices, the method comprises: executing one or more operations to fabricate the device. In some embodiments, fabrication of the device comprises manufacturing. In some embodiments, the manufacturing comprises roll-to-roll manufacturing.

[0019] In another aspect, a method of fabricating an energy manipulation device, the method comprises: (a) providing a cell assembly comprising an electrode separated from a counter electrode by a gap, the cell assembly comprising at least one temperature susceptible material above a temperature threshold, the cell assembly being an electrochemical cell assembly, (b) contacting the cell assembly with a first component of a constraint system and with a second component of the constraint system, the contacting being at least in part for coupling of the first component with the second component, and (c) utilizing a coupling agent to couple the first component with the second component at a coupling temperature above the temperature threshold, the coupling temperature resulting in harm to a prescribed operation of the device, the cell assembly being (e.g., substantially, detectably and / or measurably) unharmed by the coupling. In some embodiments, utilizing the coupling agent in a way such that the at least one temperature susceptible material willAtorney Docket No. 000456-0108-WO1 (ENX-0154.WO) not experience a temperature above the temperature threshold to an extend to cause the harm, the coupling agent being configured to increase the temperature of the first component and of the second component to generate the coupling. In some embodiments, utilizing the coupling agent to couple the first component with the second component is such that the at least one temperature susceptible material will not experience a temperature above a temperature threshold. In some embodiments, utilizing the coupling agent to couple the first component with the second component is such that the at least one temperature susceptible material will not experience a temperature above a temperature threshold. In some embodiments, the coupling agent comprises an energy beam. In some embodiments, the energy beam comprises a laser beam, an electron beam, or a plasma beam. In some embodiments, the energy beam comprises a power of at most about 100 Watts (W), or 60 W. In some embodiments, a fundamental length scale of a footprint of the energy beam onto the first component is at most 0.8 millimeters (mm), or 0.6mm. In some embodiments, the coupling agent is a laser beam. In some embodiments, the thickness of the first component and / or second component is at most about 50 micrometers (pm), 100 pm, or 150 pm. In some embodiments, the first component is thicker than the second component. In some embodiments, the first component is thicker than the second component. In some embodiments, the first component has a thickness of the second component. In some embodiments, utilizing the coupling agent comprises utilizing a progression scheme of generating the couplings such that the cell assembly and / or the second component, does not exceed the temperature threshold. In some embodiments, utilizing the coupling agent comprises utilizing a progression scheme of generating the couplings such that a central tendency of a temperature of the second component does not exceed the threshold. In some embodiments, the central tendency is an average. In some embodiments, utilizing the coupling agent comprises utilizing a progression scheme of generating the couplings such that the cell assembly and / or the second component, does not exceed the temperature threshold. In some embodiments, the progression scheme comprises avoiding a temporally successive manner generation of (a) physically successive couplings, or (b) physically successive singe files of couplings. In some embodiments, the progression scheme comprises non temporal generation of the physically successive singe files of couplings. In some embodiments, singe files of couplings that are temporally successively generated, are generated at least in part by progressing the coupling agent in the same (e.g., lateral) direction. In some embodiments, the single files of couplings that are temporally successively generated, are generated at least in part by progressing the coupling agent in opposing (e.g., lateral) directions. In some embodiments, the couplings in the single files of couplings that are temporally successively generated, are generated in a successive physical manner. In some embodiments, the couplings in the single files of couplings thatAtorney Docket No. 000456-0108-WO1 (ENX-0154.WO) are temporally successively generated, are generated in a non-successive physical manner. In some embodiments, the non-successive physical manner comprises a leapfrog type progression. In some embodiments, utilizing the coupling agent is in an atmosphere comprising at least one reactive species at a concentration lower than in an ambient environment, the at least one reactive species being configured to, during the coupling, react with (a) one or more components of the cell assembly and / or (b) one or more components of the constraint system. In some embodiments, the cell assembly comprises at least about 50- , 100-, or 150-unit cells. In some embodiments, the unit cells are horizontally stacked along a stacking axis. In some embodiments, the cell assembly forms a prismatic arrangement of the unit cells. In some embodiments, the stacking axis is parallel to a face type of the prismatic arrangement having a largest surface area among face types of the prism. In some embodiments, the prism is a rectangular prism. In some embodiments, coupling agent comprises at least one energy beam having (a) a low power of at most about 10 Watts or 100 watts and / or (b) footprint having a small fundamental length scale of at most about 200 micrometers or 500 micrometers. In some embodiments, the at least one energy beam comprises a laser beam. In some embodiments, the couplings are generated such that they are spaced apart on a single file of couplings along a lateral axis of the first component at an intra-file distance, wherein the couplings comprise spots arranged in single files parallel to each other; wherein a first set of the single files that are successive are distanced from each other by a first inter-file distance, the intra-file distance being larger than the first inter-file distance. In some embodiments, a second set of the single files that are successive are distanced from each other by a second inter-file distance, the second inter-file distance being larger than the intra-file distance and larger than the first inter-file distance. In some embodiments, the single files are of (e.g., substantially) the same length. In some embodiments, the single files comprise the same number of couplings. In some embodiments, the couplings of at least two files in the single files, are arranged parallel to each other. In some embodiments, the couplings of at least two files in the single files, are arranged in a non-staggered matter with respect to each other. In some embodiments, the couplings in the single files are arranged on axes perpendicular to a lateral direction. In some embodiments, generating the couplings is such that they withstand pressure variations of at least about 100 pounds per square inch (psi), 200psi, 450psi, or 1000psi; wherein the couplings are configured to withstand pressure variations repeatedly over the prescribed operation of the device. In some embodiments, the device is a rechargeable battery comprising the cell assembly. In some embodiments, the electrode includes active material comprising silicon. In some embodiments, the silicon is at least about 30%, 40%, or 60%, or 80% weight by weight. In some embodiments, the manner indicative of the cell assembly being in contact with the first component and / or second component during the couplingAtorney Docket No. 000456-0108-WO1 (ENX-0154.WO) comprises a geometric configuration of the cell assembly with respect to the first component and the second component. In some embodiments, the at least one temperature susceptible material is devoid of observable, measurable and / or substantial defects to an extent that the harm results during a prescribed lifetime of the device in the prescribed operation of the device. In some embodiments, the prescribed operation of the device comprises charge carrier buffering, passivating the electrode, passivation the counter electrode, chemical interaction of the cell assembly with an electrolyte mixture, cycles electrical charge and discharge of the cell assembly, storage, or any combination thereof. In some embodiments, the device is a rechargeable battery comprising the cell assembly. In some embodiments, the electrode includes active material comprising silicon. In some embodiments, the silicon is at least about 30%, 40%, or 60%, or 80% weight by weight. In some embodiments, (a) the first component is an endplate integrated with the cell assembly, (b) the second component comprises an adhesive adhering to the cell assembly, (c) the second component comprises opposing rigid bodies enclosing the cell assembly. In some embodiments, the first component comprises opposing endplates each disposed at a distal end of the cell assembly, and each coupled to the second component such that the cell assembly is disposed in an interior space of the constraint system generated by coupling the first component to the second component. In some embodiments, the adhesive is coupled to a ceramic coating of the cell assembly that remains in-tact in the device during the prescribed operation. In some embodiments, the opposing rigid bodies enclosing the cell assembly coupled with the first component cause the cell assembly to become confined (e.g., entrapped) within the cell assembly. In some embodiments, a prescribed operation of the device comprises cycling between charge and discharged state of the cell assembly. In some embodiments, the cycling comprises at least about 300 cycles, 500 cycles, 800 cycles, 1000 cycles, or 1200 cycles. In some embodiments, the couplings are metallurgical. In some embodiments, generating the couplings is at least in part by using welding and / or fusing. In some embodiments, the gap comprises a separator configured to allow separation of electrical change, and transfer of charge carriers therethrough, the at least one temperature susceptible material comprising the separator. In some embodiments, the separator comprising a polymer, a resin, any plurality of types thereof, or any combination thereof. In some embodiments, the separator comprises a ceramic. In some embodiments, the harm is optically visible using a naked human eye and / or optical microscopy. In some embodiments, the harm comprises melting, liquefication, cracking, warping, bending, or otherwise deforming the separator. In some embodiments, the cell assembly comprises spacer members configured to support an electrode current collector that is part of the electrode, the at least one temperature susceptible material comprising the spacer members. In some embodiments, the spacer members comprising a polymer, a resin, any plurality of typesAtorney Docket No. 000456-0108-WO1 (ENX-0154.WO) thereof, or any combination thereof. In some embodiments, the harm comprises melting, liquefication, cracking, warping, bending, or otherwise deforming a separator, the at least one temperature susceptible material comprising the separator. In some embodiments, the electrode and the counter electrode are stacked along a stacking axis, the first component comprising an endplate disposed at a distal end of the cell assembly, the endplate being stacked along the stacking axis. In some embodiments, the endplate comprises an elemental metal, a metal alloy, any plurality of type thereof, or any combination thereof. In some embodiments, the electrode and the counter electrode are stacked along a stacking axis; wherein the second component comprises an rigid portion having a main body and a flange at a distal end of the main body, the main body being disposed parallel to the stacking axis, and the flange being disposed perpendicular to the stacking axis. In some embodiments, the rigid portion comprises an elemental metal, a metal alloy, any plurality of type thereof, or any combination thereof. In some embodiments, the main body is configured to allow charge carriers to traverse therethrough, and maintaining dimensionality of the device within tolerances during charge and discharge cycles of the cell assembly. In some embodiments, the electrode comprises silicon. In some embodiments, a content of the silicon of the electrode is at least about 40% weight by weight. In some embodiments, the main body is coupled with the cell assembly using an adhesive structure indicative of being applied onto the main body prior to generation of the couplings. In some embodiments, the adhesive structure comprises a polymer, a resin, a plurality of types thereof, or any combination thereof. In some embodiments, the temperature threshold is a first temperature threshold, the constraint system comprises one or more temperature susceptible materials above a second temperature threshold, the coupling temperature being above the temperature threshold, the coupling temperature resulting in harm to the one or more temperature susceptible materials, the one or more temperature susceptible materials comprising the adhesive structure. In some embodiments, the main body comprises a coating configured to hinder deposition of reduced form of charge carriers thereof during operation of the device, the one or more temperature susceptible materials comprising the coating. In some embodiments, the energy manipulation device comprises a rechargeable battery. In some embodiments, the energy manipulation device comprises a lithium-ion battery. In some embodiments, the electrode comprises silicon. In some embodiments, a content of the silicon of the electrode is at least about 40% weight by weight. In some embodiments, the harm includes harm to the at least one temperature susceptible material of the cell assembly. In some embodiments, the temperature threshold is a first temperature threshold; and wherein the constraint system comprises one or more temperature susceptible materials above a second temperature threshold, the coupling temperature being above the temperature threshold, the coupling temperature resulting in harm to theAtorney Docket No. 000456-0108-WO1 (ENX-0154.WO) one or more temperature susceptible materials. In some embodiments, the couplings are generated such that the coupling is irreversible under a prescribed operating conditions of the device. In some embodiments, the prescribed operating conditions of the device abide by jurisdictional standards and / or industry standards. In some embodiments, fabrication of the energy manipulation device comprises manufacturing. In some embodiments, manufacturing the energy manipulation device comprises roll-to-roll manufacturing. In some embodiments, the method further comprises testing, buffering, storing, transporting, and / or using the device for the energy manipulation. In some embodiments, the use of the device of the energy manipulation comprises cycling the cell assembly between electrical charged and discharge states.

[0020] In another aspect, an apparatus for of fabricating an energy manipulation device, the apparatus comprises: at least one controller configured for (a) operatively couple with at least one mechanism; and (b) executing, or directing the at least one mechanism to execute, one or more operations of any of the above methods. In some embodiments, the at least one controller is configured to operatively couple with a power source and / or with a communication platform. In some embodiments, one or more of the at least one mechanism comprises the coupling agent. In some embodiments, the at least one controller comprises a feedback control scheme, a feed forward control scheme, or any combination thereof. In some embodiments, at least one controller is configured to operatively couple with at least one sensor that generates data for the feedback control scheme.

[0021] In another aspect, one or more non-transitory computer readable media comprises program instruction physically inscribed thereon, the program instructions, when read by one or more processors, are configured to (I) execute, or direct execution of, any of the above methods; and (II) the one or more operations comprising directing at least one component to execute the method, the one or more processors being configured to operatively couple with the at least one component. In some embodiments, one or more of the at least one component is of the device.

[0022] 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.

[0023] 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.

[0024] 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).Atorney Docket No. 000456-0108-WO1 (ENX-0154.WO)

[0025] 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).

[0026] 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).

[0027] In another aspect, an apparatus comprises at least one controller that is configured (e.g., programmed) to direct a mechanism used in a methodology disclosed herein to implement (e.g., effectuate) any of the method and / or operations disclosed herein, wherein the controller(s) is operatively coupled with the mechanism. In some embodiments, the controller(s) implements any of the methods and / or operations disclosed herein. In some embodiments, the at least one controller comprises, or be operatively coupled with, a hierarchical control system. In some embodiments, the hierarchical control system comprises at least three, four, or five, control levels. In some embodiments, at least two operations are performed, or directed, by the same controller. In some embodiments, at least two operations are each performed, or directed, by a different controller.

[0028] 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.

[0029] 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).

[0030] 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 twoAtorney Docket No. 000456-0108-WO1 (ENX-0154.WO) 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.

[0031] In another aspect, a computer software product, comprising a (e.g., non-transitory) computer-readable medium / media in which program instructions are stored, which instructions, when read by a computer, cause the computer to direct a mechanism used to implement (e.g., effectuate) any of the method disclosed herein, wherein the non-transitory computer-readable medium is operatively coupled with the mechanism. In some embodiments, the mechanism comprises an apparatus or an apparatus component.

[0032] In another aspect, a computer system comprising one or more computer processors and non-transitory computer-readable medium / media coupled thereto. In some embodiments, the non-transitory computer-readable medium / media comprises machineexecutable code that, upon execution by the one or more computer processors, implements any of the methods and / or operations (e.g., as disclosed herein), and / or effectuates directions of the controller(s) (e.g., as disclosed herein).

[0033] 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.

[0034] In another aspect, an apparatus comprises at least one controller is configured (i) operatively coupled with the device, and (ii) direct executing one or more operations associated with at least one configuration of the device(s) disclosed herein.

[0035] In another aspect, at least one controller is associated with the methods, devices, and software disclosed herein. In some embodiments, the at least one controller comprises at least one connector configured to connect to a power source. In some embodiments, the at least one controller being configured to operatively couple with a power source at least in part by (I) having a power socket and / or (II) being configured for wireless power transfer using inductive charging. In some embodiments, the at least one controller comprises a nonvolatile memory, e.g., a solid-state device (SSD) such as a FLASH memory. In some embodiments, the at least one controller is included in, or comprises, a hierarchical control system. In some embodiments, the hierarchical control system comprises at least three hierarchical control levels. In some embodiments, the at least one controller is included in a control system disclosed herein. In some embodiments, the at least one controller is configured to control at least one other component of a mechanism (e.g., system, device, or apparatus) disclosed herein. In some embodiments, the device disclosed herein is a component of a system, and wherein the at least one controller is configured to (i) operatively couple with another component of the system and (ii) direct operation of theAtorney Docket No. 000456-0108-WO1 (ENX-0154.WO) 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.

[0036] 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.

[0037] In some embodiments, the program instructions are of a computer product.

[0038] 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.

[0039] 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

[0040] 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.

[0041] 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

[0042] 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 theAtorney Docket No. 000456-0108-WO1 (ENX-0154.WO) features and advantages of the present disclosure will be obtained by reference to the following detailed description that sets forth illustrative embodiments, in which the principles of the present disclosure are utilized, and the accompanying drawings or figures (also “Fig.” and “Figs.” herein), of which:

[0043] Fig. 1 depicts a schematic example of various cells;

[0044] Fig. 2 depicts schematic examples of folding options for energy manipulation device (e.g., battery) components, and a current collector;

[0045] Fig. 3 depicts schematic examples of devices (e.g., batteries) and cells;

[0046] Fig. 4 depicts schematic examples of cell architectures;

[0047] Fig. 5 depicts schematic exploded views of device (e.g., battery) components;

[0048] Fig. 6 depicts illustrative examples of device (e.g., battery) components;

[0049] Fig. 7 shows images of device (e.g., battery) components;

[0050] Fig. 8 schematically shows various stages of an electrochemical cell;

[0051] Fig. 9 shows pre-charging of cells with charge carriers;

[0052] Fig. 10 shows a perspective view of a portion of a cell construct including a cell assembly and a constraint system;

[0053] Fig. 11 schematically shows a coupling spot (e.g., weld) progression strategy;

[0054] Fig. 12 schematically shows a coupling spot progression strategy;

[0055] Fig. 13 schematically shows a coupling spot progression strategy;

[0056] Fig. 14 shows various graphs related to coupling spot progression strategy;

[0057] Fig. 15 schematically shows a coupling spot progression strategy;

[0058] Fig. 16 schematically shows a coupling spot progression strategy. Fig. 16 can represent an illustrative view of a laser weld sequence, in accordance with some implementations of the subject matter of the disclosure;

[0059] Fig. 17 schematically shows a coupling spot progression strategy. Fig. 17 can represent an illustrative view of a laser weld sequence, in accordance with some implementations of the subject matter of the disclosure;

[0060] Fig. 18 shows a method flowchart for producing a cell assembly;

[0061] Fig. 19 shows a method flowchart for producing a cell assembly;

[0062] Fig. 20 depicts a schematic example of a control system;

[0063] Fig. 21 depicts a schematic example of a processing system;

[0064] Fig. 22 is an illustrative view of laser weld distance between welds for a constraint of a secondary battery, as a photographic image, in accordance with some implementations of the subject matter of the disclosures;

[0065] Fig. 23 is an illustrative flowchart of a process for welding a constraint of a secondary battery, in accordance with some implementations of the subject matter of the disclosure; andAtorney Docket No. 000456-0108-WO1 (ENX-0154.WO)

[0066] Fig. 24 is a schematic vertical cross section of portions of a cell assembly.

[0067] 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

[0068] While various embodiments of the inventions have been shown, and described herein, it will be obvious to those skilled in the art that such embodiments are provided by way of example only. Numerous variations, changes, and substitutions may occur to those skilled in the art without departing from the invention. It should be understood that various alternatives to the embodiments of the invention described herein might be employed. The various embodiments, aspects, examples, variations, alternates, and instances, disclosed herein are combinable, as appropriate.

[0069] 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.

[0070] 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.

[0071] A spatially 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.

[0072] 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. ForAtorney Docket No. 000456-0108-WO1 (ENX-0154.WO) 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.

[0073] 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.

[0074] The term “operatively coupled,” “operatively configured,” or “operatively connected” refers to a first mechanism that is coupled (or connected) to a second mechanism to allow the intended operation of the second and / or first mechanism. The coupling may comprise physical or non-physical coupling. The non-physical coupling may comprise signal-induced coupling (e.g., wireless coupling).

[0075] 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.

[0076] The symbol “*” designates the mathematical operation of multiplication, e.g., “times.”

[0077] 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.

[0078] A central tendency as understood herein comprises mean, median, or mode. The mean may comprise a geometric mean.

[0079] 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.

[0080] While the disclosure refers to a cathode as an electrode, the electrode may be an anode, as applicable.

[0081] 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.

[0082] 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 aAtorney Docket No. 000456-0108-WO1 (ENX-0154.WO)(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.

[0083] 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.

[0084] The prescribed use of the device (e.g., battery) comprises during charge-discharge cycling, during transportation, during storage, during maintenance, during upgrade, or any combination thereof. The prescribed use of the cell assembly comprises during formation of the cell assembly, during buffering of the cell assembly, during the prescribed use of the device comprising the cell assembly (e.g., the battery), or any combination thereof.

[0085] 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.

[0086] 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.

[0087] In some embodiments, the energy manipulation device includes at least one unit cell. 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 electrodeAtorney Docket No. 000456-0108-WO1 (ENX-0154.WO) connector may be also referred to herein as “an electrode terminal,” and the counterelectrode 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 counter-electrode. The gap may include a separator configured to (a) electrically isolate the electrode from the counter electrode and (b) allow traversal of charge carriers through the separator. In some embodiments, each unit cell of the set of cells, includes an electrode structure and a counter-electrode structure separated from each other by a gap. One or more (e.g., each) cells of the set of cells, each include a separator disposed in the gap. In some embodiments, the battery includes adjacent electrode sub-units. Each of the electrode sub-units has a dimension in the X-axis, Y-axis and Z-axis, respectively. The X-axis, Y-axis and Z-axis are each mutually perpendicular, akin to a Cartesian coordinate system. As used herein, the dimensions of each electrode sub-unit in the Z-axis may be referred to as a "height", the dimensions in the X-axis may be referred to as a "length" and dimensions in the Y-axis may be referred to as a "width." The electrode sub-units may be combined into one or more unit cells. A cell can include (a) at least one anodically active material mass (e.g., layer) and / or (b) at least one cathodically active material mass (e.g., layer). In some embodiments, the anodically active material is separated from the cathode by the gap. In some embodiments, the cathodically active material is separated from the anode by the gap. In some embodiments, the cathodically active material is separated from the anodically active material by the gap. The set of cells may comprise at least 2, 10, 20, 50, 100, 150, 200, 250, or 500 cells (also herein “unit 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 with a current collector. The active material mass may comprise one or more layers. The active material may form a gradient.

[0088] 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 activeAtorney Docket No. 000456-0108-WO1 (ENX-0154.WO) material. A counter-electrode tab can be an extension of the counter-electrode that is devoid of the counter-electrode active material.

[0089] 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.

[0090] In some embodiments, the cell may be coupled with a (e.g., solid) busbar. In some embodiments, the set of cells may be coupled with the (e.g., solid) busbar. The busbar may comprise a (e.g., solid) material of a class. The material class may include an elemental metal, a metal alloy, or an allotrope of elemental carbon, any plurality of types thereof, or any combination thereof. The busbar may comprise (e.g., solid) material, e.g., including one or more types of materials. At least two types of materials may belong to the same class of materials. At least two types of materials may belong to different classes of materials. A class of material may be a composite or a non-composite material. A class of material may be a tacky material (e.g., a tacky connector), or a solid material (e.g., that is non-tacky). A class of material may be a material that is fluid, or non-fluid, e.g., during manufacture of the energy manipulation device such as a battery. In an example, the (e.g., solid) busbar may comprise a metal alloy and an elemental metal. In an example, the (e.g., solid) busbar may comprise two types of metal alloys. In an example, the (e.g., solid) busbar may comprise a composite material and a non-composite material. The busbar may comprise any conductive material disclosed herein. In an example, the busbar includes copper (e.g., Cu101) and Inconel (e.g., N178). The material class can be an oxygen free material. The material class may be an electronic grade material.

[0091] In some embodiments, a busbar is attached to the current collector tabs, e.g., the attachment being assisted by the tacky connector. In an example, the busbar contacts the tacky connector that contacts the tab(s). The busbar may have a cross section of a Euclidean shape, e.g., a vertical cross section. The busbar may have a cross section of a geometric planar shape, e.g., a vertical cross section. The shape may include a polygon, anAtorney Docket No. 000456-0108-WO1 (ENX-0154.WO) ellipse, a combination thereof and / or a plurality thereof. The polygon may include a rectangle, or a plurality of rectangles. In an example, a vertical cross section of the busbar is a rectangle. In an example, the vertical cross section of the busbar comprises at least two different types of shapes, e.g., rectangles. In an example, the vertical cross section of the busbar comprises at least two types of shapes that are (e.g., substantially) the same, and that are distinct from each other. The two types of shapes may comprise the same type of material or may each be from a different type of material. The two types of shapes may comprise the same class of material or may each be from a different class of material. Two of the shapes may be separated from each other by a gap. Two of the shapes may contact each other. A cross section of the busbar may comprise an indentation, e.g., a depression. The depression may be configured to accommodate (a) folded tab(s) (b) any tacky connector, (c) any welding, or (d) any combination thereof. The depression may be configured to increase adhesion of the tab to the (e.g., solid) busbar. The increased adhesion may be at least in part by increasing the (e.g., solid) busbar’s adhesion to (i) any tacky connector and / or (ii) any welding. A contacting surface of the busbar is an exposed surface of the busbar face(s) configured to contract the (a) the tab(s), (b) any tacky connector, (c) any welding, or (d) any combination thereof. The contacting surface may undergo surface treatment before the contact. The surface treatment may be configured to increase adhesion between the (e.g., solid) busbar and (a) the tab(s), (b) any tacky connector, (c) any welding, or (d) any combination thereof. The surface treatment may comprise roughening of the contacting surface. The surface treatment may comprise etching, scraping, or printing (e.g., 3D printing). The surface treatment may comprise mechanical treatment type, chemical treatment type, any plurality thereof, or any combination thereof. The (e.g., solid) busbar may comprise one or more perforations (e.g., holes). The perforation(s) may be configured to accommodate dimensionality 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.

[0092] In some embodiments, the cell undergoes pre-loading with charge carriers, e.g., before its regular use. The pre-loading may comprise loading the cell with charge carriers, e.g., “pre-lithiation” in the case of lithium cations being the charge carriers. The pre-loading (also referred herein as “buffering”) may be performed during manufacturing and / or before providing the battery for its intended use. The pre-loading may facilitate insertion of additional charge carriers for a charge carrier source such as a lithium source, into the electrode(s) of the battery such as into the anode(s). The electrode may be a vertically short electrode. The pre-loading may replenish (e.g., irreversible) loss of the charge carriers during formation of the battery, e.g., to increase (a) efficiency of the first cycle and / or (b) cellAtorney Docket No. 000456-0108-WO1 (ENX-0154.WO) 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.

[0093] In some embodiments, a cell comprises an electrode (e.g., reference electrode), a counter electrode, separated from each other by a gap, also referred to herein as “a separation space.” The separation space may comprise a separator, e.g., having a material comprising conduits or pores, e.g., micro conduits, or micropores. The pores and / or conduits may be configured to facilitate charge carriers (e.g., ions) to propagate through the separator. The conduits may be channels. Pores of the separator may form the conduit. The battery cell may comprise, or may be coupled with, an insulator 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.Atorney Docket No. 000456-0108-WO1 (ENX-0154.WO)

[0094] In some embodiments, the cathode includes cathodically active material. The cathodically active material may include a cathodically active material including transition metal oxides, transition metal sulfides, transition metal nitrides, lithium-transition metal oxides, lithium-transition metal sulfides, lithium-transition metal nitrides, any plurality thereof, and / or any combination thereof. The cathodically active material may include transition metal elements of the transition metal oxides, transition metal sulfides, transition metal nitrides, any plurality thereof, and / or any combination thereof. The cathodically active material may include metal elements having a d-shell or f-shell. The cathodically active material may comprise metal element including Sc, Y, lanthanoids, actinoids, Ti, Zr, Hf, V, Nb, Ta, Cr, Mo, W, Mn, Tc, Re, Fe, Ru, Os, Co, Rh, Ir, Ni, Pb, Pt, Cu, Ag, Au, any plurality thereof, and / or any combination thereof. The cathodically active material may include lithium cobalt oxide (UCOO2), LiNio.5Mn1.5O4, Li(NixCoyAlz)O2, lithium metal phosphate (e.g., lithium iron phosphate, LiFePO4), Li2MnO4, V2O5, molybdenum oxysulfides, phosphates, silicates, vanadates, sulfur, sulfur compounds, oxygen (air), lithium nickel manganese cobalt oxide (Li(NixMnyCoz)O2), any combinations thereof, and / or any plurality thereof. In some implementations, the cathode (e.g., cathodically active material) is selected from transition metal oxides, transition metal sulfides, transition metal nitrides, lithium-transition metal oxides, lithium-transition metal sulfides, transition-metal phosphates, lithium-transition-metal phosphates, and lithium-transition metal nitrides may be selectively used. The transition metal elements of these transition metal oxides, transition metal sulfides, and transition metal nitrides can include metal elements having a d-shell or f-shell. Specific examples of such metal element are Sc, Y, lanthanides, actinides, Ti, Zr, Hf, V, Nb, Ta, Cr, Mo, W, Mn, Tc, Re, Fe, Ru, Os, Co, Rh, Ir, Ni, Pb, Pt, Cu, Ag, and Au. Additional cathode active materials include LiCoO2, LiNio.5Mn1.5O4, Li(NixCoyAlz)O2, LiFePO4, Li2MnO4, V2O5, molybdenum oxysulfides, phosphates, silicates, vanadates, sulfur, sulfur compounds, oxygen (air), Li(NixMnyCoz)O2, and combinations thereof. The cathode active material may comprise, S (e.g., U2S in the lithiated state), LiF, Fe, Cu, Ni, FeF2, FeOdF3.2d, FeFs, C0F3, C0F2, 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.

[0095] In some embodiments, the energy manipulation device may comprise a battery. The device may comprise Li-ion batteries, nickel metal hydride batteries, alkaline batteries, anyAtorney Docket No. 000456-0108-WO1 (ENX-0154.WO) 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.

[0096] 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 (e.g., substantially) 100% silicon - carbon anode. The anode may comprise particulate material. The anode may comprise a carbon scaffold on which silicon is deposited (e.g., layer of silicon). An exposed surface of the silicon may be coated by the, or by at least one other, of the allotropes of elemental carbon. The carbon may comprise black carbon. The carbon may include hard carbon and / or soft carbon. The carbon-silicon structure may comprise successive layers and / or scaffold. The carbon may comprise a particulate material. The particulate material may serve as a base for deposition of the one or mor layers. The particulate material may or may not include crevices. The oneAtorney Docket No. 000456-0108-WO1 (ENX-0154.WO) 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).

[0097] 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.

[0098] 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 passiveAtorney Docket No. 000456-0108-WO1 (ENX-0154.WO) 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.

[0099] In some examples, the cell comprises an active material, a charge carrier, an electrolyte, any plurality of types thereof, or any combination thereof. The active material (e.g., mass such as layer) may be added to one side or to both sides of a cell or cell stack. In some embodiments, the electrode comprises a current collector (e.g., conductor) comprising elemental metal, metal alloys, an allotrope of elemental carbon, any plurality of types thereof, or any combination thereof. The allotrope of elemental carbon 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. In some embodiments, the electrolyte may include an oxidebased electrolyte (e.g., lanthanum titanate (Lio.34Lao.56TiO3), Al-doped lithium lanthanum zirconate (Li6.24La3ZrzAlo.24011.98), Ta-doped lithium lanthanum zirconate (Li6.4La3Zri.4Tao.6012), lithium aluminum titanium phosphate (Lit.4Alo.4Tit.6(PO4)3), and / or similar such electrolytes. In some embodiments, the electrolyte may comprise a solid electrolyte (e.g., sulfide-based electrolyte such as lithium tin phosphorus sulfide (LiioSnP2Si2), lithium phosphorus sulfide (13-U3PS4), lithium phosphorus sulfur chloride iodide (Li6PS5C1o.91o.i), and / or similar such electrolytes. The electrolyte may compriseAtorney Docket No. 000456-0108-WO1 (ENX-0154.WO) ethylene carbonate, diethylcarbonate, dimethylcarbonate, ethylmethylcarbonate, propylene carbonate, any derivatives thereof, or any combination thereof.

[0100] Fig. 1 shows in example 100 a schematic representation of a cell, the cell comprising an electrode 102a - “C” (e.g., a cathode), and an opposing electrode which is a counter electrode 105a - “A” (e.g., an anode). A separator is disposed in separator space (e.g., gap) 103 - “B.” The battery cell is disposed in a battery having housing 109. The housing can be rigid, or flexible. The housing may include a rigid portion and / or a flexible portion. The battery can optionally have an insulator 104. The insulator may comprise one or more materials comprising a ceramic, a polymer, or a resin. The battery may comprise one or more insulator types. In an example, a polymer may fill a cathode gap, and alumina fills a cathode gap, the gap being from the edge of the cell to its immediately adjacent edge of the case (also herein “casing”). In some embodiments, insulator may comprise a non-electrically conductive material. The ceramic may comprise alumina (AI2O3), zirconia (ZnCh), magnesium oxide (MgO), boron nitride (BN), mullite, boehmite, or silicon carbide (SiC, e.g., in pure form). Under normal conditions during use of the battery, the main current is a load current 106 passing from one electrode to its opposing electrode, and through separation space 103. When volume 104 comprises the insulator, the insulator contacts at least at opposing sides 102b and 102c of electrode 102a and at opposing sides 105b and 105c of counter-electrode 105a.

[0101] 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.

[0102] 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.

[0103] 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, 0.2Atorney Docket No. 000456-0108-WO1 (ENX-0154.WO) 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 with 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.

[0104] 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.

[0105] 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 aAtorney Docket No. 000456-0108-WO1 (ENX-0154.WO) 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.

[0106] In some embodiments, one or more cells are disposed within a housing 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 be configured to 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.

[0107] 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 be asymmetrical in shape. The Euclidean 3D shape may comprise a cylinder or a prism. The prism may be a Euclidean prism, or an amorphous prism. In some embodiments, the battery is a prismatic battery. In some embodiments, the battery is a cylindrical battery. The battery may have a first FLS such as a height (e.g., Fig. 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 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.

[0108] 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 batteryAtorney Docket No. 000456-0108-WO1 (ENX-0154.WO) 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.

[0109] 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 be configured to electrically separate one cell from another. The electrode assembly 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 theAtorney Docket No. 000456-0108-WO1 (ENX-0154.WO) cathode, the extension being in a direction perpendicular to the cell stacking axis. The endplate and the rigid constraint portion may be of the same material type or of different material types. For example, the endplate and the rigid constraint portion may comprise stainless steel. For example, the rigid constraint portion may comprise stainless steel (e.g., SS-301 or SS-316), and the endplates may comprise aluminum. The rigid constraint portion may comprise stainless steel, or Inconel. Any portion of the constraint (e.g., the rigid constraint portion) may comprise a coating, e.g., a lacquer. The coating may comprise ClearClad, polyimide, or an electrodeposition coating. The electrodeposition coating may comprise Shimizu type coating. The coating may hinder deposition of charge carrier plating such as lithium plating, e.g., during use of the cell assembly. In some embodiments, the constraint system is devoid of a coating.

[0110] 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 - an anode busbar, ending with anode contact 411 forming a terminal tab. Each cathode “C” in the battery is operatively coupled (e.g., connected) with a current collector such as 416, the cathode current collectors being coupled in parallel to a main cathode current collector 417 - cathode busbar, ending with cathode contact 412 - terminal cathode tab.

[0111] 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 anode contact 461 - terminal anode tab. Each cathode “C” in the battery is operatively coupled (e.g., connected) with a cathode current collector such as 466, the cathode current collectors being coupled in parallel to a main cathode current collector 467, ending with cathode contact 462 - terminal cathode tab. 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.

[0112] 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, areAtorney Docket No. 000456-0108-WO1 (ENX-0154.WO) 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.

[0113] 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.

[0114] 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 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*,Atorney Docket No. 000456-0108-WO1 (ENX-0154.WO) 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.

[0115] The energy storage device may comprise at least one constraint (e.g., a brace, or a harness). The constraint may be configured to (e.g., substantially) maintain constant dimensions and / or volume of the device during the charge / discharge operations. The constraint may be configured to maintain internal pressure in the device, e.g., during the charge / discharge operations. The internal overpressure in the device may be at most about 100PSI, 150PSI, 200PSI, 500PSI, 1000 PSI, 2000 PSI, 3000 PSI, 5000PSI, or 10000PSI. The internal overpressure in the device may be at most about 50 PSI, 100PSI, 150PSI, 200PSI, 450PSI, 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.

[0116] In some embodiments, the battery cell set is disposed in an orthogonal stacked configuration.

[0117] 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, 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.

[0118] Fig. 5 shows in example 500 an exploded view of a pair of constraints 501a and 501b 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 aAtorney Docket No. 000456-0108-WO1 (ENX-0154.WO)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.

[0119] 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.

[0120] 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 such as a rectangular box.

[0121] 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 counterelectrodes 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.

[0122] In some embodiments, the interior of the casing is separated from an exterior of the casing, e.g., to hinder reactive specie(s) in the external environment to traverse to the interior environment such as to cause the harm. Terminals configured to conduct theAtorney Docket No. 000456-0108-WO1 (ENX-0154.WO) electrical current flow are configured to allow electrical connectivity of the external environment with the cell(s) disposed in the interior of the housing. The housing comprises a seal to separate the interior environment of the housing from its exterior environment. The terminals extend through the seal from the interior of the housing to the external environment. Each of the terminals can be coupled with the housing (e.g., at the seal area) by coupler. The coupler may comprise a compressible material such as a malleable material. The terminal may be secured to the housing by an adhesive, e.g., at the seal. The terminal may be secured to the seal at least in part by the adhesive and / or by the compressible material. The compressible material may be an adhesive. The compressible material and / or the adhesive, may comprise a polymer, a resin, a combination thereof, or a plurality of types thereof. The adhesive may be (e.g., substantially) confined to the seal. The adhesive may comprise polypropylene or epoxy glue. The fuse may be reinforced by an adhesive, e.g., to any portion of the device such as disclosed herein. The fuse may be located (e.g., and reinforced to) a portion of the device sufficiently distant from susceptible material(s) such that when the fuse activates, the harm will not be made due to activation of the susceptible material(s). The susceptible material may participate in the chemistry of the device, e.g., of the cell. The susceptible material(s) may comprise any of the active materials of the cell, any electrolyte, any separator, any insulator, any divider, any current collector, any busbar, any adhesive, any plurality (e.g., of types or otherwise) thereof, or any combination thereof. The compressible material may be disposed in the seal, in an interior of the housing, in the exterior of the housing, or any combination thereof. In some embodiments, the terminal is compressed by the compressible material, which is compressed by the seal of the housing.

[0123] In some examples, the battery is disposed in a housing comprising a pouch. The pouch may insulate the battery content (e.g., the cell therein) from one or more reactive agent in the ambient environment external to the pouch. The pouch may enclosure the case of the battery, and the cell(s) housed therein. The pouch may comprise one or more layers. The one or more layers may include a material comprising a polymer, a resin, an elemental metal (e.g., strip, film, foil, and / or powder thereof), or a metal alloy (e.g., strip, film, foil, and / or powder thereof). The one or more layers may include one or more of these materials. The pouch may have an external surface having a color comprising black, silver, or white.

[0124] 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 theAtorney Docket No. 000456-0108-WO1 (ENX-0154.WO) 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 constrain may anisotropically constraint the expansion of the cell stack. 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 such as 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 to arrows 703). Diffusion of charge carriers may occur through perforations in the constraint system (e.g., perforation 651 of Fig. 6).

[0125] 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 (e.g., substantially) 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 (abbreviated herein as “PPL”) 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).

[0126] 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 introduction of the electrolyte mix may be after generating the cell construct including the cell assembly coupled with the constraint system. 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 byAtorney Docket No. 000456-0108-WO1 (ENX-0154.WO) 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).

[0127] Example 750 shows battery cell 752 wrapped (e.g., 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 700 may provide improved thermal conductivity compared to the rolled configuration of example 750. The stacked cell layout shown in example 700 may provide improved diffusion for the entering materials compared to the rolled configuration of example 750. The stacked cell layout shown in example 700 may provide improved heat dissipations as compared to the rolled configuration of example 750.

[0128] Fig. 8 schematically shows a cause for the expansion and contraction of a cell during charge and discharge states. Example 800 shows an anode discharge states. Anode active material such as 801 is separated from cathode active material such as 802 by a gap in which separator 803 is disposed. The separator has a perforation (e.g., conduit such as a pinhole) through which charge carriers can transverse from one electrode to its counter electrode. Example 830 shows an anode charged state. Anode active material such as 831 is separated from cathode active material such as 832 by a gap in which separator 833 is disposed. As compared to the anode discharged state shown in example 800, the anode active material is inflated, e.g., expanded. The cathode active material is depicted as occupying (e.g., substantially) the same volume between the charged and discharged state.

[0129] Example 860 shows an anode in which charge carriers are provided. The charge carriers such as 861 (e.g., lithium cation) become surrounded by a mobile electrolyte 862 such as a fluid or semi-fluid electrolyte, e.g., solvent or gel. The charge carriers propagate through solid electrolyte interphase (SEI) 835. Deposition 863 of a reduced from of the charge carriers 866 may occur on at least one edge type of the set of cells (e.g., anode) - at its interface; followed by diffusion of the charge carriers into the electrode active material portion 864, e.g., comprising silicon and / or an allotrope of elemental carbon such asAtorney Docket No. 000456-0108-WO1 (ENX-0154.WO) graphite. The deposition may comprise accumulation of the reduced form of the charge carriers at the interface.

[0130] Fig. 9 shows an example of a charge carrier (e.g., Lithium) source 901 located immediately adjacent to an edge of a set of cells in battery 902. Due to the cell’s arrangement having their stacking direction along the Y axis, and their edges pointing towards opposing sides along the X direction, it may be impractical to diffuse the charge carriers along the stacking axis, e.g., due to longer and / or inhomogeneous diffusion. In this cell set configuration, it may be more beneficial to allow the charge carriers to diffuse from one or both opposing side along the X axis. The example in Fig. 9 is depicted with respect to a Cartesian coordinate system. The stacked cells may span tenths of millimeters in the stacking direction, e.g., at least about 10, 50, or 100 millimeters. The cells may span a length along the X axis of at least about 1 , 2, 3, 5, 6, or 8 millimeters. The cells may span a length along the X axis of at most about 2, 3, 5, 6, 8, or 10 millimeters. The cells of battery 902 may be held by a constraint system (e.g., Fig. 6, 650). The constraint system may comprise perforations (e.g., holes) that facilitate penetration of the charge carriers from source 901 through the constraint, to the cells of battery 902, e.g., the holes in constraint system 501a and 501 b. The source 901 may contact one or both opposing sides of the battery. Fig. 9 shows source 901 contacting one side of battery 902.

[0131] Fig. 9 illustrates, in example 900, an electrochemical cell assembly comprising a set of stacked electrodes 902 disposed between constraint portions, adjacent to which are charge carrier precursor card 901 . 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. End plates such as endplate 904, and unit cells such as unit cell 906, are disposed as part of the cell assembly 902. A stacking axis parallel to axis 908 is defined along the Y-axis stacking direction of the cell assembly 902. The stacked electrodes 902 are oriented along a Y-axis stacking direction, with active material edges directed toward the X axis. A charge carrier source 901 is positioned adjacent to the edge of the electrode stack. Diffusion of charge carriers may occur from source 901 through perforations in constraint portions. The perforations may correspond to holes in the constraint system, e.g., Fig. 5, 501a and 501b. The diffusion may proceed along the X direction to enter the stacked cells 902. The configuration may reduce inhomogeneous charge distribution and support direct interfacial delivery. The stacked cells 902 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 500 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 mmAtorney Docket No. 000456-0108-WO1 (ENX-0154.WO) 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). The end plates such as 904 are at the distal ends of cell assembly 902. The endplates are each disposed at terminal ends of the stack of unit cells, and along the stacking axis of the unit cells. The unit cell 906 comprises an anode, a cathode, and a separator arranged to define an electrochemical structure. The unit cells are arranged in series along the stacking axis to form the cell assembly 902. The stacking axis parallel to 908 is a longitudinal distance defining the overall length of the cell assembly 902 along the Y-axis stacking direction.

[0132] 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 essential components such as essential chemical(s) for the function of the battery, e.g., depletion of the charge carriers.

[0133] 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.

[0134] 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.Atorney Docket No. 000456-0108-WO1 (ENX-0154.WO)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, etc.) 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. However, there are currently inadequate solutions to replenish the starting materials required, e.g., the FEC. When the FEC concentration decreases in the electrolyte (e.g., to allow for more cycles of mending the SEI layer), the higher FEC concentration may decrease the efficiency of the battery and / or cause safety concerns for the battery. Higher concentration of FEC may result in generating gas, e.g., the higher the temperature experienced by the battery. Concentrations of FEC above 40% could form solids that decrease the efficiency of the battery. Higher concentration of FEC may increase the impedance of the battery and / or increase the viscosity of the electrolyte. Increasing the viscosity of the electrolyte can reduce the travel rate of the charge carriers in the battery. The gas generated may comprise hydrogen (H2), carbon dioxide (CO2), carbon monoxide (CO), methane (CH4), short aliphatic (e.g., CXH2X+2 such as ethane), or any combination thereof. The active FEC concentration can be most about 0.5%, 1%, 5%, 10%, 15%, or 30% v / v. The active FEC concentration can be between any of the aforementioned percentage values, e.g., from about 1% to about 20%, from about 0.25% to about 30%, from about 0.25% to about 5%, from about 5% to about 15%, or from about 15% to about 30%. In an example, the cell has at most about 15% active FEC available in the electrolyte mixture.

[0135] The passivation layer may result from an electrochemical reduction of electrolyte component(s) (e.g., FEC) at the electrode interface. The passivation layer may allow charge carriers (Li+) transport through the passivation layer while hindering (e.g., blocking) electron flow, e.g., to hinder (e.g., prevent) decomposition of other electrolyte components. The passivation layer may stabilize the active material (e.g., of the anode) at least in part byAtorney Docket No. 000456-0108-WO1 (ENX-0154.WO) hindering (e.g., impeding or substantially preventing) direct contact between the electrons and the other electrolyte components, thus reducing degradation of the electrolyte and improving cycle life. The passivation layer may comprise inorganic salts, e.g., LiF, U2CO3, organic compounds (e.g., lithium alkyl carbonates, Fluoroethylene Carbonate (FEC) and vinylene carbonate (VC) polymerization products). Generation of the passivation layer may consume the charge carriers, e.g., irreversibly. Lithium may be converted into Lithium carbonate and lithium fluoride in the reduction reaction to form the passivation layer, which reaction may be irreversible.

[0136] In some embodiments, charge carriers (e.g., Li ions) reside in a cathode when the battery is in a discharged state, and reside in the anode when the battery is in a charged state. For example, when a battery charges, charge carriers (e.g., carrier ions) migrate into one or more electrode active materials. As the charge carriers traverse (e.g., move) in and out of the active material of the electrodes, the active material undergoes a volume change. The movement in an out of the active material may be referred to as ingress and egress of the charge carriers relative to the active material. The amount of expansion may differ depending on the active materials used for the electrode. For example, a graphite electrode may expand by about 6% to 10% when the graphite electrode is charged. In another example, a silicon electrode may expand up to 300% when the silicon electrode is charged. In another example, a silicon oxide electrode may expand up to 210% when the silicon oxide electrode is charged. In another example, an electrode comprising silicon may expand up to about 20%, 50%, 75%, 100%, 200%, 300%, or 350% when the silicon electrode is charged, the percentage being volume per volume. In some embodiments, graphite electrodes require less starting material (e.g., fluoroethylene carbonate (FEC)) than silicon electrodes because the graphite electrodes expand less.

[0137] 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.,Atorney Docket No. 000456-0108-WO1 (ENX-0154.WO) substantially) normal to their face having the largest surface area. The electrode has an electrode face having the largest surface area, and the counter-electrode has a counterelectrode face having the largest surface area. In some embodiments, there is a difference in a volume of the cell between a state of charge and a state of discharge of an electrode of the cell. The volume of the cell may repeatedly and / or reversibly alter between the state of charge and the state of discharge repeatedly. The reversible discharge may not be completely reversible, e.g., there may be an attrition in the properties of one or more components of the cell during a cycle of charge / discharge. The repeated cycling between the state of charge / discharge may comprise at least about 200 cycles, 500 cycles, 800 cycles, 1000 cycles, 1200 cycles, or 1500 cycles. In some embodiments, there is a difference in a volume of the cell between a state of charge and a state of discharge of an electrode of the cell. The change in volume may comprise a change in at most about 20%, 25%, 50%, 100%, 200%, 300%, or 400% of an initial volume of the cell. The change in volume may comprise a change in at least about 10%, 25%, 50%, 100%, 200%, or 300% of an initial volume of the cell. The change in volume may comprise a change in any of the 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.”

[0138] 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.

[0139] In some embodiments, electrons are formed in an operation of the cell, which electrons can further react with cell component(s). As the charge carriers move in the battery (e.g., in the cell), electrons are also moving. The electrons may travel from the current collector to the active material coupled with the current collector. When the active material contacts the current collector, such movement of electrons may be direct. When the active material does not contact the current collector, the movement may be indirect. The indirect movement may be through another active material (e.g., particle), through a conductor, or through a semiconductor. In an example, an allotrope of elemental carbon facilitates the movement of electrons from the current collector to the active material and / or from an active material mass of an electrode to another active material mass of the electrode. The allotrope of elemental carbon may comprise carbon nanotube, carbon fiber, any plurality of types thereof, or any combination thereof. The electrons may react with one or more chemicals inAtorney Docket No. 000456-0108-WO1 (ENX-0154.WO) the device such as in the cell, e.g., some of which reactions may be detrimental to the battery’s chemistry such that they diminish (e.g., harm) the device’s requested performance. For example, the electrons may destabilize metal oxides during the charge / discharge cycles, e.g., due to slippage of transition metal layers, phase transitions and / or electrochemical strain. Mitigation (e.g., reduction) of the reactivity of the electrons in the battery cell may include causing confinement of the electrons to retard (e.g., reduce, deter and / or substantially prevent) reaction of the electrons with the material(s) in the device, e.g., during the prescribe operation conditions of the battery and / or during the prescribed lifetime of the battery. Generation of a passivation layer that helps confine the electrons in the active material mass and / or impede their reaction with components of the device (e.g., of the cell) external to the passivation layer, may mitigate the harmful reactivity of the electrons.

[0140] 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.

[0141] In some embodiments, the energy manipulation device is rechargeable. The device may be configured to 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,Atorney Docket No. 000456-0108-WO1 (ENX-0154.WO) from about 3C to about 30C, from about 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 an 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, 71gr., 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 200Atorney Docket No. 000456-0108-WO1 (ENX-0154.WO) 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.

[0142] 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.

[0143] In some embodiments, the cell is pre-loaded with charge carriers, e.g., to form an initial passivation layer. During the initial charge process (e.g., buffering such as pre- lithiation), certain starting materials (e.g., FEC) are consumed to contribute to the formation of a passivation layer, e.g., an SEI layer. The passivation layer may be the result of the electrons and / or charge carriers reacting with the electrolyte in a reduction reaction. In some embodiments, the electrolyte(s) is / are chosen such that the reduction reaction results in the passivation layer having certain properties. For example, the passivation layer may comprise a solid or semisolid (e.g., gel). The passivation layer may be porous, e.g., to allow the charge carriers to migrate into and out of the electrode active material, e.g., silicon and / or graphite. The passivation layer may allow charge carriers (e.g., Li+) to pass through it while hindering (e.g., blocking) electron flow, to reduce (e.g., prevent) decomposition of electrolyte(s). The passivation layer may stabilize the active material, e.g., at least in part by hindering (e.g., preventing) direct contact of the electrode active material with any active components (e.g., of the electrolyte mixture), such that degradation of critical cell component(s) is reduced and / or the cycle life of the battery (e.g., the cell) is improved, in comparison to a situation in which no passivation layer is formed. The passivation layer may comprise a (e.g., inorganic) salt, an organic compound, a polymer, a resin, a composite, any plurality thereof, or any combination thereof. The salt may be the salt of the charge carrier. The organic compound may be made from a carbonate precursor. The organic compounds may comprise, or may be made of a precursor comprising, lithium alkyl carbonates, fluoroethylene carbonate (FEC), vinylene carbonate (VC), polymerization products thereof, aAtorney Docket No. 000456-0108-WO1 (ENX-0154.WO) plurality of types thereof, or any combination thereof. In some embodiments, the passivation layer comprises a different chemical form of the charge carriers such as lithium. The passivation layer may (e.g., readily) form (e.g., deposit) on one or more surfaces of the active material of the cell, e.g., of the electrode and / or of the counter-electrode. The passivation layer may be a decomposition product comprising the charge carriers and / or electrolyte mixture components. Although formation of the passivation layer may be requested for the stability of the battery and / or cell thereof, some of the starting materials (e.g., FEC) and / or the electrons, may be irreversibly bound to the passivation layer, and thus are removed from regular operation of the cell, e.g., during its charge and discharge cycles.

[0144] 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 (UBF4), 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.

[0145] In some embodiments, the cell comprises an anode separated by a gap from an anode. The cell may comprise a separator disposed in the gap. The cells may be elongated, e.g., may assume a shape of an elongated box. The face of the cell opposing the largest surface area face of the electrode (e.g., anode or cathode) may have an aspect ratio of at least about 10:1, 15:1, 20:1 , 35:1, or 50:1 , the aspect ratio being a length (e.g., Fig. 6, 631)Atorney Docket No. 000456-0108-WO1 (ENX-0154.WO) 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.

[0146] In some embodiments, the architecture of the device comprising the stacked electrodes described herein (e.g., Figs. 3, 5-6, and 9) allow 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 wrapped (e.g., jelly roll) cell configuration, or cell having a smaller aspect ratio, e.g., and having vertically stacked electrodes along a stacking axis. 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).

[0147] The prescribed use of the device (e.g., battery) comprises during charge-discharge cycling, during transportation, during storage, during maintenance, during upgrade, or any combination thereof. The prescribed use of the cell assembly comprises during formation of the cell assembly, during buffering of the cell assembly, during the prescribed use of the device comprising the cell assembly (e.g., the battery), or any combination thereof. The normal operation conditions of the device may be such that the device (e.g., minimally) abides by jurisdictional standards, and / or industry standards.

[0148] In some embodiments, the methodologies disclosed herein provide for a constraint system for a cell assembly. The constraint system comprises physically coupled (e.g., welded) structural components adapted for reducing dimensional alteration of the cell assembly, e.g., volumetric alteration below a threshold. The physical coupling can be effectuated using fusing of immediately spatially adjacent casing sections. The fusing process can comprise melting, sintering, or at least partially liquefying. The fusing process can comprise welding, e.g., fusion welding. The coupling may include welding, e.g., laser welding, arc welding, and / or gas welding. The welding may include fusion welding and / or solid-state welding. The dimensions may be altered during the prescribed use of the device, e.g., prescribed use under the normal operation conditions of the device. The dimensions may be altered during charge, discharge, and / or other volumetric change. The welded structural components may physically wrap the cell assembly with the constraint system, e.g., leaving opposing side openings. The welded structural components may physically couple the constraint system with the cell assembly, e.g., directly or indirectly through a separation interface. The separation interface may beAtorney Docket No. 000456-0108-WO1 (ENX-0154.WO) porous. The separation interface may comprise at least one ceramic material type, e.g., alumina and / or boehmite. The separation interface may comprise an insulator, e.g., may be an electrically insulating layer. The constraint system may maintain mechanical integrity under internal pressure variations, e.g., while promoting compatibility with energy density requirements and / or manufacturing conditions.

[0149] In some embodiments, the constraint system comprises (i) one or more endplates, (ii) one or more rigid constraint portions, (iii) an optional coating, (iv) an adhesive layer, or (v) any combination thereof. The optional coating may comprise an insulator. The optional coating may be configured to deter deposition of a reduced form of the charge carriers, e.g., may be configured to deter lithium plating on the constraint portion in which the coating is deposited. The constraint system may comprise any subset, or any combination, of the aforementioned components, e.g., depending at least in part on a design configuration of the cell assembly, operation conditions, and / or chemical makeup of the cell assembly such as of its active material. As used herein, the term “constraint system” refers to a structural assembly comprising one or more rigid constraint portions, one or more endplates, an optional insulating coating and / or adhesive layer. The term “constraint body” refers to the rigid portion of the constraint system comprising a planar middle section and two opposing flanges. The rigid portion and flanges of the constraint body can be made from a single unit of material, e.g., a bent sheet such as of metal.

[0150] In some embodiments, the constraint system is adapted to withstand pressure variation generated during cycling of the cell assembly. The pressure variation may include an overpressure as compared to the ambient environment external to the device such as battery. The pressure may be applied along a lateral direction of the constraint system, defined as perpendicular to a stacking axis of the cell assembly (e.g., Y-direction in Figs. 5 and 6). The constraint system may maintain structural integrity under pressure variation of at least about 450 pounds per square inch (psi), 500psi, 600 psi, 700 psi, or 800 psi. The pressure variation may be at most about 900 psi, 1000 psi, 1100 psi, or 1200 psi. The pressure variation may be of any value between the aforementioned values, e.g., from about 500 psi to about 1200 psi, for example while minimizing permanent deformation of the constraint structure. The pressure variation may be measured along the lateral axis (e.g., X axis in figs. 5 and 6). The pressure variation may be measured relative to the pressure of the ambient environment (about 14.7 psi). The maximal pressure in the cell may differ based on the anode active material and the charge carriers used. For the case of lithium ions, Si-C may exert about half the pressure exerted by SiOx, e.g., Si-C may exert about 450 PSI in a configuration, and SiOx about 1200 PSI in an otherwise similar configuration.

[0151] In some embodiments, the constraint system is adapted to maintain dimensional stability of the cell assembly during volumetric change. The volumetric change may beAtorney Docket No. 000456-0108-WO1 (ENX-0154.WO) associated with charge and discharge cycles of the cell assembly. The volumetric change undergone by the cell assembly constrained by the constraint system, may be at most about 2%, 3%, 5%, 8%, 10%, 12%, or 14%. The volumetric change may be of any value between the aforementioned values, e.g., from about 2% to about 14%, or from about 2% to about 10%. The volumetric change may be in accordance with applicable jurisdictional standards and / or industry standards. The standards may include dimensional change limits and / or mechanical strain thresholds defined by product safety or certification standards, e.g., UN 38.3, IEC 62133, UL 2580, or analogous regional standards.

[0152] In some embodiments, the constraint system is adapted to accommodate volumetric variation (e.g., expansion) of the cell assembly during the use of the cell assembly, e.g., during cycling. The variation may occur along a direction parallel to a lateral face of the constraint system (e.g., X-direction in figs. 5 and 6). The constraint system may allow partial decoupling between one or more internal surfaces and the constraint body during maximal expansion. The constraint system may allow decoupling while minimally (e.g., substantially without) compromising the structural function of the constraint.

[0153] In some embodiments, the constraint system is adapted to absorb and / or redirect expansion energy generated during volumetric change of the cell assembly. The expansion energy may act along orthogonal and / or lateral directions relative to the constraint structure. For example, the directions aligned with an X axis and / or a Z axis orientation. The X axis and / or a Z axis orientation are shown in Figs. 6 and 5. The constraint system may reduce localized stress concentration in regions such as an edge of the rigid (e.g., middle) portion adjacent to a flange. The reduction in stress concentration may minimize a likelihood of structural defects, e.g., cracking and / or breakage.

[0154] In some embodiments, the constraint system is adapted to minimize crack initiation and / or irreversible structural damage during the prescribed lifetime of the device. The term “prescribed lifetime” may refer to the operational duration or cycle count defined for the device in accordance with its intended application, certification requirements, or product specifications, including standard cycling and environmental profiles applicable in relevant jurisdictions. The number of charge-discharge cycles may be at least about 1000, 1200, 1500, or 1800. The number of charge-discharge cycles may be at most about 2000, 2500, 3000, or 3500. The number of charge-discharge cycles may be of any value between the aforementioned values, e.g., from about 1000 to about 3500. The operating temperature for the device (e.g., battery) may be at least about -45°C, -40°C, -35°C, or -30°C. The operating temperature may be at most about 60°C, 70°C, 75°C, or 80°C. The operating temperature may be of any value between the aforementioned values, e.g., from about -45°C to about 80°C. The constraint system may maintain structural performance within prescribed conditions, e.g., under standard cycling and environmental profiles.Atorney Docket No. 000456-0108-WO1 (ENX-0154.WO)

[0155] In some embodiments, the constraint system is adapted to hinder (e.g., measurably and substantially prevent) cascading structural failure across the constraint body. The constraint system may promote formation of localized defects, e.g., chain reactions in one portion. The formation of localized defects may minimize (e.g., substantially avoid) structural propagation of defects into the rest of the constraint system.

[0156] In some embodiments, the constraint body comprises a rigid (e.g., middle) portion having a pattern of openings. The pattern may or may not be uniform and / or repetitive. The pattern may comprise at least one repetition along the middle portion of the constraint body. The openings may be adapted to facilitate charge carrier buffering. The open area of the rigid constraint portion may be at least about 15%, 18%, 20%, or 22%. The open area may be at most about 25%, 30%, 35%, or 40%. The open area may be of any value between the aforementioned values, e.g., from about 15% to about 40%. In an example, the open area is at least 20% of the surface area of the rigid portion of the constraint system.

[0157] In some embodiments, the constraint system is adapted to support energy density requirements by comprising a structure with reduced thickness. The thickness of the constraint system measured in micrometer (pm) may be at least about 10 micrometers (pm), 20 pm, 30 pm, or 40 pm. The thickness may be at most about 50 pm, 55 pm, 60 pm, 70 pm, 100 pm, or 150 pm. The thickness may be of any value between the aforementioned values, e.g., from about 10 pm to about 70 pm, or from about 10 pm to about 150 pm. The thickness of the constraint system may be selected to reduce risks to safety and / or structural function, while minimally adding weight to the resulting device such as battery, and while minimally adding volume to the resulting device such as battery, e.g., to minimally reduce its energy density.

[0158] In some embodiments, the constraint body comprises at least two opposing rigid constraint portion(s) (also referred to as “rigid portion” herein). The rigid portions may be separated from each other by a gap. The rigid portion may be joined to respective endplates disposed at opposing distal ends of the cell assembly, e.g., and along the stacking axis. The endplates may be stacked along a stacking axis shared with one or more electrodes of the cell assembly. The endplates and the electrodes may share a common aspect ratio. The aspect ratio may be of an elongated rectangle. Each rigid constraint portion may comprise a planar (e.g., substantially flat) middle portion and at least two opposing flanges. The flange may extend orthogonally to the planar middle portion. The planar middle portion of each rigid portion may comprise at least two types of openings (e.g., perforations). The openings may be adapted to promote uniform diffusion of charge carriers therethrough and / or into the cell assembly. The rigid portions may be coupled with (e.g., welded with) the endplates such that each endplate joins to two flanges, each flange belonging to a different rigid constraint portion. The coupling of the endplate to the rigid portion (e.g., to the flange thereof) may be configured to be irreversible in the prescribed operating conditions of the device such as battery. TheAtorney Docket No. 000456-0108-WO1 (ENX-0154.WO) planar middle portion of each rigid portion may span between the opposing flanges. Two opposing sides of the planar middle portion of the rigid portion may each terminate by a flange. The two flanges may be directed towards a direction away from the middle portion. The planar portion of the flange may be (e.g., substantially) normal to the planar portion of the middle portion. The planar middle portion may define a structural face of the constraint system. The rigid constraint portion (e.g., each flange thereof and / or the middle portion), may have a thickness of at least about 20 pm, 30 pm, 40 pm, or 50 pm. The thickness may be at most about 100 pm, 120 pm, 150 pm, or 200 pm. The thickness may be of any value between the aforementioned values, e.g., from about 20 pm to about 200 pm. The thickness of the middle portion of the constraint may be any thickness disclosed herein. The endplate may have a thickness of any value disclosed herein for the rigid constraint portion. The endplate may have a thickness (e.g., substantially) similar to that of the rigid portion. The endplate may have a thickness different from that of the rigid portion, e.g., thinner or thicker.

[0159] In some embodiments, the middle portion of the constraint body is uncoated.

[0160] In some embodiments, the middle portion of the constraint body is coated. The coating may be configured to deter the plating of reduced form of charge carriers thereon, e.g., lithium plating. The coating may comprise an electrically insulating material. The insulating material may comprise a polymer, a resin, any plurality thereof, or any combination thereof. The coating may comprise a lacquer. In an example, materials such as ClearClad, and / or a polyimide (e.g., Kapton), may be used to provide the coating. The coating may comprise an anodized material. The coating may be chemically inert with respect to components of the cell assembly and / or chemistry of the electrochemical cell. The middle portion may be with minimized (e.g., substantially without) insulation. The middle portion may comprise an elemental metal, a metal alloy, an allotrope of elemental carbon, a ceramic, a plurality of types thereof, or any combination thereof. The middle portion may comprise a composite material, or a noncomposite material. For example, the middle portion is made of a metallic material comprising stainless steel. The flanges of the constraint system may be with minimized (substantially without) coating, for example to facilitate physical coupling between the flanges and the endplates, e.g., using a phase change process and / or metallurgical process. The metallurgical process may comprise fusion. The fusion may comprise sintering, melting, or liquefying. The fusion may comprise welding. The metallurgical process may comprise heating and / or pressurizing (e.g.., solid state welding). The openings in the middle portion may be with minimized (e.g., devoid) of a coating. The coating may be applied (i) to the middle portion, (ii) to the entire rigid portion of the constraint body, and / or (iii) to selected regions. The region selectivity may be based at least in part on processing constraints and / or coupling interfaces. An adhesive layer may be operatively coupled with the middle portion of the constraint body. An adhesive layer may adhere to the rigid material directly and / or to the coating, dependingAtorney Docket No. 000456-0108-WO1 (ENX-0154.WO) on coating configuration of the constraint system. The adhesive may bond to a surface of the cell assembly, e.g., to exposed active material and / or current collectors. The cell assembly may be coated by the separation interface such as disclosed herein, e.g., a porous insulating layer. The separation interface may comprise a particulate composition. The separation interface may comprise a polymer, a resin, a ceramic, any plurality of types thereof, or any combination thereof. In an example, the separation interface includes alumina and / or boehmite.

[0161] In some embodiments, the adhesive adheres to the rigid constraint portion. The adhesive may adhere to an insulating layer optionally covering the rigid constraint portion. The rigid constraint portion may comprise an elemental metal, a metal alloy, an allotrope of an elemental metal, (e.g., carbon fiber), a composite material, any plurality of types thereof, or any combination thereof. The constraint body may comprise stainless steel, e.g., SS 301 or SS 316. The constraint body may comprise aluminum. The adherence of the constraint body to the cell assembly may occur during charge and discharge cycling. The adherence of the constraint body to the cell assembly may occur during volumetric changes. For example, the volumetric change occurs during formation processes. The formation processes may include initial buffering with charge carriers and / or formation of a passivation layer. The adhesive interaction may support mechanical stabilization of the constraint body during early-stage electrochemical processes, for example, initial expansion during cell formation. The adhesive interaction may reduce mechanical decoupling during long-term cycling, for example, during prescribed lifetime of a device. The flanges may be (e.g., substantially and / or measurably) devoid of the adhesive, e.g., to facilitate effective and / or durable coupling of the flanges with the endplates, the coupling being such as disclosed herein.

[0162] The constraint system is made of material(s) and connections that withstand pressure variation and / or maintains its volume within a tolerance threshold, during the prescribed use of the device such as a battery. The material of the constraint system may be (e.g., substantially) inert of the chemistry of the device in which it is installed such as a battery. In an example, the material(s) of the constraint system are (e.g., substantially) inert and / or resistive to hydrogen embrittlement. The material may be (e.g., substantially) resistive to one or more defects comprising plastic deformation, fracture, cracking, buckling (e.g., compressive failure), line defects (e.g., dislocations), surface defects (e.g., plating), voids, grain boundaries, stacking faults, twin boundaries, cracks, or any combination thereof. The material may be (e.g., substantially) resistive to the defect(s) in a way that does not harm the prescribed operation of the device, e.g., of the cell assembly.

[0163] In some embodiments, the constraint system comprises one or more endplates. The endplates may be structurally coupled to the rigid constraint body to define a bounded region for supporting a cell assembly. Each endplate may contribute to dimensional control of the cellAtorney Docket No. 000456-0108-WO1 (ENX-0154.WO) assembly during cycling, along at least one axis (e.g., of a Cartesian coordinate system such as in Figs 5 and 6). For example, the endplate forms a mechanically anchored boundary along a stacking axis. The endplates may be composed of (e.g., substantially) the same material as the rigid constraint portions, or may be composed of a different material. In an example, the endplates are made of at least one stainless steel type. The material of the endplates may be selected to reduce interfacial stress concentration during volumetric expansion. The endplates may support coupling (e.g., weld formation) at the interface with one or more of the flanges. Each endplate may act as an independent mechanical and / or thermal buffer, during the use of the cell assembly such as during the cycling. The material and / or thickness of the endplates may be tuned separately from the rigid constraint portions. The separation may allow the flange-to-endplate coupling (e.g., weld) to dissipate heat into the endplate efficiently, e.g., more efficiently than into the middle constraint portion. The (e.g., enhanced) thermal sink capacity of the endplates may reduce peak temperature in the region of the cell assembly during the coupling operation (e.g., welding).

[0164] In some embodiments, the endplates are disposed along the stacking axis at distal ends of the cell stack. Each endplate may be positioned at an outermost end of the aligned electrode layers. The stacking axis may traverse a sequence of alternating (e.g., interdigitated, or interlaced) cathodes, anodes, with each pair of anode and cathode separated by a gap. The gap may comprise an electrically insulating separator. The endplates may define the physical boundaries of the electrode region along the stacking direction. The location of the endplates may stabilize the relative arrangement of the electrode layers during electrochemical cycling. Electrochemical cycling as used herein refers to repeated transitions between charged and discharged electrical states during use of the cell assembly (e.g., and of the device). Thermal cycling as used herein refers to changes in temperature that occur during the prescribed use of the device, e.g., during charging, discharging, resting, and / or storage. The mechanical support provided by the endplates may reduce positional drift of the electrode layers. The mechanical support may promote (e.g., and maintain) uniform pressure distribution in the cell assembly throughout the cell assembly.

[0165] In some embodiments, at least one endplate is positioned adjacent to an electrode (e.g., anode) within the cell assembly. Each endplate may contact the outermost electrode in the stacking direction. The outermost electrode may be an anode or a cathode, e.g., depending on cell architecture. The placement of the endplate adjacent to the electrode may influence the thermal and / or electrochemical stability of the assembly. The electrode region may be sensitive to heat exposure during coupling, e.g., welding. The direct contact with the endplate may facilitate localized heat spreading during physical coupling (e.g., welding) operations. The proximity of the endplate to the electrode (e.g., active material thereof) may influence expansion dynamics in buffering, passivation layer formation and / or electrical cyclingAtorney Docket No. 000456-0108-WO1 (ENX-0154.WO) stages, of the cell assembly. The proximity of the endplate to the electrode may influence adhesive interaction in buffering, passivation layer formation and / or electrical cycling stages, of the cell assembly.

[0166] In some embodiments, each endplate has a defined thickness measured along the stacking axis of the cell assembly. The thickness may be at least about 20 pm, 30 pm, 40 pm, or 50 pm. The thickness may be at most about 80 pm, 100 pm, 120 pm, 150 pm, 200 pm, 250 pm, or 300 pm. The thickness may be of any value between the aforementioned values, e.g., from about 20 pm to about 150 pm, or from 20 pm to 300 pm. The endplate may have any endplate thickness disclosed herein. The endplate and the rigid portion may or may not have the same thickness. The thickness of the endplate may influence heat dissipation and / or coupling (e.g., weld) propagation along the joining interface. A thinner endplate (e.g., 30 pm) may promote conformal bonding with the flange. The selected thickness may influence deformation behavior during the operation of the device, e.g., during pressure-induced cycling. A thicker endplate (e.g., 100pm) may act as a thermal buffer during heating. The heating may be associated with the coupling, e.g., with the welding. The endplate and / or rigid portion may act as a heat conditioning system, e.g., as a heatsink. The heat conditioning system may be passive, e.g., a heatsink.

[0167] In some embodiments, the thickness of the flange and the thickness of the endplate is (e.g., substantially) same. In some embodiments, the thickness of the flange and the thickness of the endplate are different. Each flange may define a coupling (e.g., weld) contact surface of the rigid constraint portion. The relative thickness between the flange and the endplate may affect thermal resistance during the coupling process. A flange that is thinner than the endplate may allow faster heating at the coupling interface. A flange that is thicker than the endplate may result in slower temperature rise and / or altered coupling morphology. The selected thickness relationship may be chosen based at least in part on coupling uniformity, process speed, and / or heat dispersion characteristics, e.g., heat dispersion characteristics disclosed in association with Fig. 7.

[0168] In some embodiments, the material of the endplate is (e.g., substantially) the same as the material of the flange. In some embodiments, the material of the endplate is different from the material of the flange. The flange may comprise a metallic material, e.g., stainless steel. The endplate may comprise a metallic material with similar or different thermal conductivity. When components comprise the same material, the coupling (e.g., welding) interface may exhibit symmetric and / or uniform coupling (e.g., fusion). When the materials are different, the coupling interface may exhibit directional heat flow and / or asymmetric thermal gradients. A mismatch in thermal conductivity may be used to localize and / or disperse heat along the coupling region. The material combination may be selected to control coupling quality, mechanical stiffness, and / or processing cost.Atorney Docket No. 000456-0108-WO1 (ENX-0154.WO)

[0169] In some embodiments, the endplates are mechanically joined to the rigid constraint portions to define a closed structural frame around the cell assembly, e.g., a sleeve within which the cell assembly is disposed. The coupling (e.g., mechanically joining) may involve physical bonding between each endplate and two opposing flanges, each flange belonging to a different rigid constraint portion, e.g., of two opposing constraint portions. The method of coupling may involve localized heating, e.g., laser welding, applied at controlled energy, controlled sequence, controlled heating, controlled timing, and / or controlled spacing intervals. The coupling design may influence thermal stress distribution, material deformation, and / or mechanical integrity of the assembled device (e.g., battery). The structural geometry, thermal limits, weld formation strategies, and / or laser configurations used to execute the coupling are described herein.

[0170] In some embodiments, each endplate is physically coupled (e.g., joined) with flanges. Two of the flanges coupled with an endplate may each belong to a different rigid constraint portion. Two of the flanges coupled with an endplate may each belong to an opposing rigid constraint portion. Two of the flanges may be coupled with opposing edges of the endplate in a (e.g., substantially) planar (e.g., flat) configuration. The joined structure may define a substantially continuous sleeve surrounding the cell assembly. The sleeve may be a prismatic sleeve. The sleeve may have two opposing open ends. The open ends may permit operations such as electrode extension, electrode contraction, tab extension, tab coupling with busbar, gas management, temperature conditioning, and / or electrolyte exchange. The prismatic geometry may maintain structural closure around the cell assembly, e.g., while leaving functional access points. The sleeve configuration may enable mechanical restraint on volumetric changes undergone by the cell assembly. The constraint system may minimize (e.g., substantially avoid) enclosing all (e.g., six) faces of the cell assembly. The constraint system may minimize internal displacement during volumetric cycling. The flange coupling configuration with the endplates may simplify targeting coupling operations and / or improve coupling symmetry along the sides (e.g., both sides) of an endplate. The flange (e.g., dual flange) coupling design may simplify laser targeting and / or improve welding symmetry along the sides (e.g., both sides) of the endplate.

[0171] In some embodiments, the coupling process involves localized heating at the interface between the flange and the endplate. The temperature at the endplate during coupling of the flange with the endplate (e.g., during welding) may be at least about 30°C, 40°C, 45°C, or 50°C. The temperature at the endplate during coupling of the flange with the endplate, may be at most about 80°C, 90°C, 100°C, 120°C, or 150°C. The temperature at the endplate during coupling of the flange with the endplate, may be of any value between the aforementioned values, e.g., from about 30°C to about 150°C. The internal component(s) (e.g., separator) of the cell assembly may comprise at least one material with a lower thermal tolerance asAtorney Docket No. 000456-0108-WO1 (ENX-0154.WO) compared to the flanges and / or to the endplate. In an example, the flanges and the endplate are metallic, and the separator comprises an organic polymer. The coupling temperature range of the flanges with the endplate may be selected based at least in part on the thermal sensitivity of the separator material. The defined upper temperature limit (e.g., upper temperature threshold) during the coupling, may allow formation of structural coupling with minimally (e.g., substantially without) exceeding the deformation threshold of the at least one material having the lower temperature tolerance. The structural couplings (e.g., connecting spots or joining spots) may comprise welding spots. In an example, the defined upper temperature limit during the welding, allows formation of structural coupling with minimally (e.g., substantially without) exceeding the deformation threshold of the separator layer(s). By aligning the coupling (e.g., weld) energy profile with the temperature threshold (e.g., the separator’s melting range), the coupling process may permit localized bonding while keeping the integrity and functionality of the cell assembly in the constraint system. The coupling process may (e.g., substantially) maintain functional separation between electrodes. The thermal alignment may enable in-situ coupling of the constraint body with the endplates, while keeping the integrity and functionality of the cell assembly in the constraint system. The in-situ coupling of components of the constraint, while the cell assembly is disposed in its interior space, may be implemented while minimizing (e.g., substantially without) requiring preremoval and / or external shielding, of the cell assembly. Such manner of coupling the components of the constraint system with the cell assembly disposed in its interior space, promotes ease of manufacture, reduces number of manufacturing operations, minimizes manufacturing errors, increases consistent reproducibility of the manufactured device and / or increases the yield of the manufactured device. The element having the lowest heat tolerance in the cell construct, (e.g., comprising polymer / resin) may have a lower melting point, glass transition, or liquification temperature. The threshold temperature may be at most about 65°C, 70°C, 80°C, 90°C, 100°C, 120°C, 150°C, 200°C, 250°C, 300°C, or 400°C. The temperature at the endplate during coupling of the flange with the endplate, may be of any value between the aforementioned values, e.g., from about 65°C to about 400°C, from about 65°C to about 150°C, or from about 65°C to about 250°C.

[0172] In some embodiments, the endplates are coupled (e.g., joined) with the flanges of the constraint body by welding. The weld may be formed by localized delivery of thermal energy to the interface between the flange and the endplate. The energy may be sufficient to cause interfacial fusion of the metallic materials of the welded components, e.g., the flanges and the endplate. The coupling (e.g., weld) interface may be located in direct proximity with internal layers of the cell assembly. The internal layers may include (i) a separator, (ii) an electrolyte, (iii) at least one active material and / or (iv) spacer member. The spacer member may be configured to support the current collector (e.g., tab). In an example, the lateral length of theAtorney Docket No. 000456-0108-WO1 (ENX-0154.WO) cathode is smaller than that of the anode. The spacer member(s) can occupy a lateral empty space from cathode active material, relative to the anode. Opposing spacer members can be disposed at opposing sides of a cathode current collector portion devoid of cathode active material (e.g., tab). The spacer members can be stacked in the direction of the stacking axis, as part of the cell stack. The spacer member(s) may comprise a polymer, a resin, any plurality of types thereof, or any combination thereof. The spacer member may or may not be of the material type of the separator. The spacer member may be a tape. The spacer member may comprise a tacky material, e.g., configured to couple with a portion of the cathode current collector devoid of an active material. The separator may comprise a ceramic, a polymer, a resin, any plurality of types thereof, or any combination thereof. The at least one active material may comprise the anodic active material, the cathodic active material, or a combination thereof, e.g., the active material may be any of those disclosed herein. At least one of the internal components of the cell assembly (e.g., layers) may exhibit material sensitivity to heat, e.g., greater than the heat sensitivity of the constraint system, e.g., of the endplates and flanges of the constraint system. An uncontrolled application of coupling (e.g., welding) energy may initiate structural and / or chemical failure within the cell assembly. Possible outcomes of uncontrolled application of coupling energy may include deformation in one or more components of the cell assembly, e.g., separator melting, separator cracking, spacer member melting, spacer member cracking, decomposition of electrolyte, degradation of active material, and / or ignition events associated with a thermal runaway. The one or more components may comprise the separator, the spacer member, the electrode active material layer, the counter electrode counter material layer, the electrode current collector, the counterelectrode current collector, the electrode busbar, the counter-electrode busbar, or any combination thereof. The electrode active material layer may comprise active material, filler, binder, charge propagation aids, any plurality of types thereof, or any combination thereof. The charge propagation aids may comprise an allotrope of elemental carbon such as carbon nanotubes, carbon nanoparticles, or any combination thereof. The allotrope of elemental carbon may be any of the ones disclosed herein. The coupling (e.g., weld) interface may be located in direct proximity with components of the constraint system that are susceptible to temperature change, e.g., the constraint coating and / or constraint adhesive. The components of the constraint system that are susceptible to temperature change may comprise a polymer, a resin, any plurality of types thereof, or any combination thereof. The coupling (e.g., welding) approach disclosed herein may be adapted to deliver controlled energy to the area (e.g., spot) to be coupled such as a welding spot. The coupling approach may (e.g., substantially) maintain thermal isolation of temperature-sensitive components of the cell assembly and / or of the constraint system.Atorney Docket No. 000456-0108-WO1 (ENX-0154.WO)

[0173] In some embodiments, localized thermal accumulation occurs when coupling locations (e.g., spots) are generated at locations that are too close to each other within a given region of the constraint system. The increase in temperature may exceed the thermal threshold of the at least one component of the cell assembly susceptible to temperature, if spatially adjacent coupling zones are heated in rapid succession - in time adjacent succussion. The thermal accumulation may originate from direct energy input and / or secondary conduction through the metal. The risk of the thermal accumulation may be elevated when the time between successive coupling locations is short. The risk of the thermal accumulation may be elevated when the spatial gap between successive coupling spots (also herein “couplings”) is narrow. To reduce the likelihood of thermal overload, the welds may be generated in spatially separated locations. A coupling (e.g., weld) pattern may be arranged so that two consecutive couplings do not induce overlapping thermal fields. The separation distance may exceed the thermal diffusion length during the cooling interval after coupling. A coupling sequence may be selected to distribute heat away from critical regions of the cell assembly, e.g., that are susceptible to heat above a threshold.

[0174] In some embodiments, couplings (e.g., welds) are generated in spatially distinct zones along the flange-to-endplate interface. Each coupling zone may be selected to allow sufficient thermal dissipation before initiation of a subsequent weld in an adjacent region. The cooling time between coupling (e.g., weld) events may be longer than the localized thermal relaxation time of the coupling pool such as weld pool. A dwell period may allow the peak coupling temperature to decay below a thermally neutral baseline. Sequential placement of couplings with insufficient cooling intervals may result in cumulative heating and / or thermal bridging. A coupling (e.g., welding) system disclosed herein applies a time-domain separation strategy that complements spatial decoupling of coupling sites. The dual-mode control of position and timing disclosed herein may enable high-density weld formation. The dual-mode control may minimize (e.g., substantially avoid) violating thermal constraints of the internal cell assembly. The time-regulated sequence may support consistent coupling (e.g., weld) morphology. The time-regulated sequence may reduce variability in heat-affected zones across the constraint interface.

[0175] In some embodiments, the coupling (e.g., welding) system performs control of each coupling pool. The control may be a real-time control, e.g., during the coupling operation. The coupling parameters may be adjusted dynamically based at least in part on thermal feedback, material response, historical measurements, feed forward control, thermal dissipation simulation, and / or energy absorption rate. The thermal control may comprise a physics simulation, e.g., thermal dissipation simulation, and / or energy absorption rate. The simulation may consider the material(s) to be coupled, the coupling methodology (e.g., welding or sintering), the coupling spot size, fluid dynamics of heat, phase transition temperature,Atorney Docket No. 000456-0108-WO1 (ENX-0154.WO) spatially adjacent heating, temporally adjacent heating, or any combination thereof. The realtime control may facilitate localized optimization of each coupling spot, e.g., weld. The coupling system may enable selective tuning of energy input, spot size, and / or dwell time, at individual coupling sites. The use of feedback-based control may reduce the likelihood of coupling and / or other defects, e.g., under variable interface conditions. The temporal precision of the approach disclosed herein may reduce spatial overheating of the endplate and / or of the cell assembly disposed in the constraint system. The temporal precision of the approach may increase process duration, reliability, repeatability, consistency, or any combination thereof, as compared to a sequential coupling process that does not consider the effect of heating above the temperature threshold. In some embodiments, the temporal precision of the coupling operation does not (e.g., substantially) increase process duration, as compared to a sequential coupling process that does not consider the effect of heating above the temperature threshold. The coupling sequence may follow a non-successive pattern. The non-successive strategy may distribute couplings across a single linear array - a single file of couplings such as welds. The non-successive strategy may distribute couplings across multiple parallel files. The order of couplings may skip between non-adjacent sites and / or non-adjacent files, e.g., to reduce thermal crosstalk. The use of alternating coupling (e.g., weld) files (e.g., sequential series of couplings) may promote uniform heat dispersion along the flange and / or diminish the risk of overheating heat susceptible component(s) in the cell assembly. The non-successive approach may minimize process complexity, e.g., while substantially preserving thermal control.

[0176] In some embodiments, the coupling (e.g., welding) process is conducted in a defined atmospheric environment. The atmosphere may be ambient, e.g., surrounding air at room conditions. The atmosphere may be depleted of one or more reactive species as compared to the ambient environment, e.g., water vapor and / or oxygen. The depleted atmosphere may comprise at least one inert gas, e.g., argon and / or nitrogen. The depleted atmosphere may comprise clean dry air (CDA), e.g., with controlled humidity and / or oxygen content. The gasphase composition of the environment may influence the oxidation kinetics of the coupling (e.g., weld) interface. Reactive species may promote interfacial contamination, porosity, dislocation, uncontrolled solidification, and / or premature solidification. The use of an atmosphere different from the ambient atmosphere, may promote certain metallurgical microstructures, metallurgical bonding, and / or low defect density. The defect may comprise porosity, dislocations, grain boundaries, or any combination thereof. Atmospheric composition may be tuned based at least in part on material type, coupling energy (e.g., laser wavelength), and / or coupling spot duration. The controlled gas environment may reduce post-coupling (e.g., post-wed) surface irregularities and / or improve long-term structural performance.Atorney Docket No. 000456-0108-WO1 (ENX-0154.WO)

[0177] In some embodiments, the coupling utilizes a laser. Unless specifically indicated, the laser can be any of the lasers disclosed herein, e.g., the laser generating an energy beam having the large FLS, or the laser generating the energy beam having the small FLS, the energy beam FLS being generated without additional optics to any ones included with the laser as received from the laser supplier. Unless specifically indicated, the laser beam can be any of the laser beam disclosed herein, e.g., the energy beam having the large FLS, or the energy beam having the small FLS, the energy beam FLS being generated by the laser as received from the laser supplier - excluding additional (e.g., external) optics.

[0178] In some embodiments, the coupling (e.g., welding and / or sintering) process is performed under a gas stream. The gas stream may be directed, e.g., flow in a certain direction and / or towards a certain location. The gas may be delivered as a continuous flow or a pulsed flow, e.g., during a coupling operation. The gas stream may comprise a noble gas. The gas stream may comprise a gas that is (e.g., substantially and / or measurably) non-reactive with the coupling material and / or with the cell assembly, during the coupling operation. The gas stream may be oriented across the coupling interface, e.g., to displace surface-bound material debris. The gas stream may clean the surrounding atmosphere of the coupled components, during the coupling. The surrounding atmosphere may include debris generated as a consequence of the coupling operation, e.g., soot, splatter, spatter, or any combination thereof. The gas flow may clear the surrounding atmosphere from plasma, gas borne debris, e.g., particulate matter such as dust, dislodged cell assembly pieces, insulating material (e.g., ceramics such as alumina and / or boehmite), carbonaceous residue, or any combination thereof. The gas flow may remove debris such as soot, vaporized metal, splatter, spatter, and / or ejected particulates. The stream may hinder (e.g., measurably and / or substantially prevent) accumulation of debris (e.g., soot and / or carbonaceous residue), in proximity to the coupling (e.g., weld) site. The debris (e.g., material removed by ablation, spallation, dicing, and / or other vapor-phase residue) may accumulate near the coupling interface. The coupling may be induced by at least one laser beam. The presence of the debris in the optical path from the laser to the coupling site, may alter the absorption and / or reflection profile, of incoming laser energy utilized for the coupling. The alteration may lead to laser beam distortion. The beam distortion may result in coupling (e.g., weld) asymmetry, variable depth, process inconsistency, variability in coupling strength, and / or process instability. The directed gas stream may flow through the optical path. The directed gas stream may remove the transient byproducts from the optical path. Gas-assisted clearing of the optical path may maintain beam collinearity and / or focal precision. The gas delivery mechanism may be integrated within the coupler (e.g., welding head) and / or implemented through a localized external nozzle. The flow of gas in the area of the coupling site, may be within a processing cone of the laser beam processing the coupling sites.Atorney Docket No. 000456-0108-WO1 (ENX-0154.WO)

[0179] In some embodiments, the cell assembly with the constraint system is maintained at room temperature during coupling of the constraint sections (e.g., welding and / or sintering). The surrounding temperature of the coupling area can be an ambient temperature of the facility at which the coupling occurs. The surrounding temperature of the coupling area may range from about 20°C to about 25°C. The coupling may or may not be performed in a dedicated enclosure, e.g., a clean room setting. The surrounding temperature may depend at least in part on ambient and / or process-controlled conditions. The room-temperature baseline may act as a thermal sink for the coupled interface. The room-temperature baseline (e.g., from about 20°C to about 25°C) may establish a favorable thermal gradient between the coupling (e.g., weld) site and the surrounding structure. The gradient may promote rapid heat extraction from the heated zone, e.g., melt pool. Accelerated cooling may reduce the spatial extent and / or temporal duration of the heat-affected zone. A steep (e.g., sharp) cooling profile may enable directional solidification, promotion of a certain microstructure type, and / or reduce grain boundary irregularities. The steep cooling profile may be generated with a molten metal cools to ambient (e.g., room) temperature. The relatively low initial temperature may permit closer spacing between adjacent couplings (e.g., welds), such as with minimal cumulative thermal buildup, the low initial temperature may be relative to the coupling temperature. The coupling may or may not include active preheating of one or more coupled components. The coupling procedure may, or many not, include staged temperature management system such as cooldown systems. The room temperature setting for the coupling may reduce (e.g., eliminate) a need for the cooldown system. The coupling (e.g., welding) that initiates from components held at a room temperature, may support high-throughput manufacturing of constraint systems, e.g., with reproducible coupling integrity, simplified process, and / or reduced cost. In an example, the weld interface momentarily heats to a melting temperature of at least 700°C during energy delivery, and thereafter cools to room temperature when welding ceases. In this example, an adjacent region to the coupling, containing the temperature susceptible components (e.g., separator and / or spacer member) may remain below a thermal threshold (e.g., of about 150°C) due to the room-temperature starting condition and / or rapid lateral heat dissipation. The thermal threshold may be below a temperature at which the component most susceptible (e.g., spacer member, separator, constraint adhesive, constraint coating) to temperature undergoes an irreversible and / or detrimental change to the integrity of the generated device such as battery. In an example, the temperature differential between the room-temperature base and the weld zone exceeds 950°C during laser activation. For example, a base temperature of 22°C and a weld zone peak of 1000°C establishes a thermal gradient sufficient to initiate rapid directional solidification. The coupling (e.g., welding) approach disclosed herein can establish in-situ structural coupling of the constraint body with the endplates. The coupling (e.g., welding) approach may minimizeAtorney Docket No. 000456-0108-WO1 (ENX-0154.WO)(e.g., substantially avoid) disassembling and / or thermally isolating, the underlying cell assembly. The system disclosed herein allows direct coupling (e.g., fusing and / or welding) of metallic flanges to endplates in proximity to polymeric and / or electrochemically active materials. The strategy disclosed herein leverages spatial sequencing, thermal isolation, atmospheric control, and / or controlled (e.g., feedback-tuned) energy delivery. The combination of attributes disclosed herein allows for localized metallurgical bonding. The combination may (e.g., substantially) maintain functional and / or chemical integrity of the manufactured device (e.g., battery). The coupling method may reduce assembly operations, improve process efficiency, and / or support high-precision integration of mechanically robust constraint geometries over the prescribed lifetime of the manufactured device, e.g., under its prescribed operating conditions.

[0180] In some embodiments, the coupling (e.g., welding) process is implemented using a laser system selected to match the structural and / or thermal requirements of the constraint system. The selection parameters may include beam power, spot size, wavelength, modulation mode, beam profile, and / or pulse frequency. The system may comprise continuous wave, pulsed laser operation, or a combination thereof. The beam profile may comprise a gaussian, a top-hat, or a corona (e.g., doughnut) shaped beam profile. The laser may or may not be designed for the specific coupling operation. The laser may or may not be selected from welding-specific platforms. The laser may be repurposed for non-welding applications, e.g., laser designed for dicing, for ablation and / or for spallation. The beam profile may be selected to shape energy distribution across the coupling interface. The range of compatible laser configurations disclosed herein may support a coupling strategy that is tunable in energy density, optical footprint, and / or thermal coupling efficiency. This flexibility may enable precise control of localized heat delivery, e.g., in spite of proximity of the coupling spot to temperature-sensitive battery materials. In some embodiments, the multi-variable laser design space disclosed herein forms a key enabler of in-situ coupling of constraint components directly onto live or pre-assembled cell assemblies.

[0181] In some embodiments, the coupling (e.g., welding) system comprises a laser with output power and / or optical footprint selected to minimize energy transfer beyond the coupling interface. The laser may have a beam having a smaller FLS and / or smaller power density. The laser power may be at least about 5 Watts (W), 8 W, 10 W, or 15 W. The laser power may be at most about 50 W, 80 W, 90 W, or 100 W. The laser power may be of any value between the aforementioned values, e.g., from about 5 W to about 100 W. The FLS may correspond to the effective optical diameter at the coupling interface, e.g., beam diameter. The FLS may be at least about 100 pm, 150 pm, 180 pm, or 200 pm. The FLS may be at most about 180 pm, 200 pm, 250 pm, 300 pm, 400 pm, or 500 pm. The FLS may be of any value between the aforementioned values, e.g., from about 100 pm to about 500 pm. A laser beam within theAtorney Docket No. 000456-0108-WO1 (ENX-0154.WO) range mentioned herein may deliver controlled energy to the flange-endplate interface. The energy input may limit thermal coupling to nearby battery structures, e.g., by using a selected coupling spot preparation scheme. The defined optical scale and / or propagation scheme may promote localized metallurgical bonding without generating extended heat-affected zones. The coupling conditions may be selected to support direct attachment of constraint components to cell assemblies comprising thermally sensitive materials, e.g., polymer, resin, electrolyte components, or any combination thereof. The coupling energy and / or propagation schemes, may be controlled using the control system disclosed herein. The propagation scheme may include temporal and / or spatial propagation of the energy beam along the coupling interface.

[0182] In some embodiments, the coupling (e.g., welding) system comprises a laser selected to achieve a metallurgical bond at the flange-endplate interface. One or more properties of the laser beam may govern at least in part the spatial extent of energy delivery during each coupling event, e.g., welding and / or fusion. The one or more laser beam properties may include the FLS for the selected laser beam, irradiation time, propagation velocity, and / or laser power. The laser propagation may be discontinuous, e.g., a stop and propagate type movement. The laser may propagate from one spot to another, while stopping at a spot location and irradiating on that spot continuously or discontinuously (e.g., pulsing). The laser may have a larger FLS and / or larger energy density. A larger FLS of the laser beam (e.g., as disclosed herein such as at least about 500 pm or 600 pm) may allow full-width bonding of thick flange regions. The thick flange region may have a width of at least about 150 pm or 200 pm. The larger FLS may distribute thermal input broadly across the interface. An average power output (e.g., power density) of the selected laser (e.g., having the larger FLS) measured in watt (W), may be at least about 200 W, 250 W, 500 W, or 1000 W. The average power output of the laser may be at most about 500W, 100W, 1200 W, 1300 W, 1400 W, or 1500 W. The average power output may be of any value between the aforementioned values, e.g., from about 200 W to about 1500 W. A peak output power of the laser (e.g., having the larger FLS) measured in kilowatt (kW), may be at least about 5 kW, 6 kW, 6.5 kW, or 7 kW. The peak output power of the laser may be at most about 7kW, 12 kW, 15 kW, 20 kW, or 25 kW. The peak output power of the laser may be of any value between the aforementioned values, e.g., from about 5 kW to about 25 kW. The laser in the power range mentioned herein may support rapid formation of structurally complete couplings across metallic interfaces. A peak power of the laser of at least about 5 kW, may enable substantially full material penetration within short pulse durations, e.g., less than 100 nanoseconds (ns). The selected power regime of the laser may support coupling integrity, for example, while minimizing (e.g., substantially without) thermal exposure to adjacent battery components.Atorney Docket No. 000456-0108-WO1 (ENX-0154.WO)

[0183] In some embodiments, a laser beam is used for coupling of constraint portions. The laser beam has a beam diameter corresponding to the large FLS, such as disclosed herein. The large FLS may be at least about 300 pm, 350 pm, 400 pm, 500 pm, or 600 pm. The large FLS may be at most about 500 pm, 600 pm, 700 pm, 750 pm, 800 pm, or 850 pm. The large FLS may be of any value between the aforementioned values, e.g., from about 350 pm to about 850 pm. The FLS may define the optical footprint of energy deposition at the flangeendplate interface. A large FLS may increase the area of thermal exposure, for example, while reducing peak energy density. The broader laser beam profile may promote bonding across flange regions having increased thickness, e.g., a large thickness of at least about 150 pm or 200 pm. The extended thermal spread may reduce local stress concentration. The extended thermal spread may promote uniform couplings (e.g., weldings) formation across the coupling surface.

[0184] In some embodiments, the laser system used for coupling constraint portions operates at a near-infrared wavelength region. The wavelength of the laser beam measured in nanometer (nm), may be at least about 1050 nm, 1060 nm, 1065 nm, or 1080 nm. The wavelength of the laser beam may be at most about 1065 nm, 1080 nm, 1085 nm, 1090 nm, 1095 nm, or 1100 nm. The wavelength of the laser beam may be of any value between the aforementioned values, e.g., from about 1050 nm to about 1100 nm. The laser beam may be delivered through an optical fiber platform. The selected laser beam wavelength may exhibit (e.g., high) absorption in the material from which the constraint portions to be coupled are made of, such as stainless steel, aluminum, and / or other (e.g., reflective) constraint materials. The use of an optical fiber laser may support efficient beam delivery, e.g., with high spatial coherence. Fiber-based delivery may facilitate (e.g., enable) integration with compact optical heads and / or automated coupling (e.g., welding) systems. The wavelength range of the laser beam may be selected to optimize (e.g., maximize) coupling efficiency of the constraint portions, e.g., without exceeding the temperature threshold in the control scheme effectuated in the coupling. The laser beam’s wavelength range may be selected to minimize (e.g., substantially avoid) reflection-induced losses at the coupling interface.

[0185] In some embodiments, the laser operates in a controllable mode, e.g., manually and / or using a control system such as disclosed herein. The operation mode may comprise a continuous wave (CW) mode, a pulsed mode, or any combination thereof. In an example, the laser is a continuous wave laser that is turned off / on to generate a pulsed mode at selected timeframes. A continuous wave laser may be modulated by on-off switching to produce discrete pulses. The laser may maintain an average power output during the modulation. The laser may maintain a (e.g., substantially) constant peak power throughout the pulsed cycle. The modulation method may be selected based at least in part on coupling geometry, material absorption, laser one or more laser beam properties (e.g., such as disclosed herein), and / orAtorney Docket No. 000456-0108-WO1 (ENX-0154.WO) thermal boundary conditions (e.g., threshold(s)). Pulsed energy delivery may allow controlled energy per coupling (e.g., weld) event. The pulse delivery may minimize (e.g., substantially avoid) modification in beam optics. The CW operation may support long seam coupling (e.g., welding) with stable thermal input. Modulated CW systems may provide a compromise between depth control and / or process efficiency. The modulation flexibility may enable tailoring the coupling (e.g., welding) in geometrically constrained regions of the constraint body.

[0186] In some embodiments, the laser delivers energy in discrete pulses measured in millijoule (mJ). The pulse energy may be at least about 0.2 mJ, 0.3 mJ, 0.4 mJ, or 0.5 mJ. The pulse energy may be at most about 0.5 mJ, 0.7 mJ, 0.9 mJ, or 1 .0 mJ. The pulse energy may be of any value between the aforementioned values, e.g., from about 0.2 mJ to about 1 .0 mJ. The selected pulse energy may determine the volume of molten material generated per weld event. A lower energy pulse may at least in part limit the depth of thermal penetration into the flange and / or endplate. A short pulse duration may at least in part limit the depth of thermal penetration into the flange and / or endplate. A (e.g., substantially and / or measurably) controlled pulse energy of the laser beam may facilitate (e.g., enable) surface-confined coupling (e.g., fusion), e.g., in regions located near temperature sensitive materials such as disclosed herein, e.g., separator layers of the cell assembly. The energy level of the laser beam may be tuned to achieve metallurgical bonding, for example, while substantially maintaining thermal isolation of nearby cell components. The use of sub-millijoule pulses may support high-resolution coupling spot (e.g., welds) placement across narrowly spaced constraint features such as the flange.

[0187] In some embodiments, the laser emits a sequence of discrete pulses at a defined frequency measured in hertz (Hz). The pulse frequency may be at least about 100 Hz, 500 Hz, 1 kHz, 5 kHz, 10kHz, 50kHz, 100kHz, or 500kHz. The pulse frequency may be at most about 100 Kilohertz (kHz), 500KHz, 800kHz, 1000 kHz, 1200 kHz, or 1500 kHz. The pulse frequency may be of any value between the aforementioned values, e.g., from about 100 Hz to about 1500 kHz. The laser may operate as at most a nanosecond-class, at most a picosecond-class source, and / or at most a femtosecond-class source. The frequency may control the temporal spacing between successive energy delivery events. A lower frequency (e.g., of about 1 kilohertz or 5 kilohertz), may allow more time for temperature conditioning (e.g., cooling) between adjacent pulses. The temperature conditioning may be passive, e.g., passive dissipation of heat. The passive dissipation of heat may be by conduction, convection and / or radiation. The convection may be aided by the flow of gas, e.g., utilized to clean the optical path of the laser to the constraint portions to be coupled. The conduction may comprise transfer of heat within the constraint system and / or to the cell assembly disposed in the constraint system. A higher frequency, e.g., about 500 kilohertz or 1000 kilohertz, mayAtorney Docket No. 000456-0108-WO1 (ENX-0154.WO) promote smoother coupling continuity across scanning paths of the laser beam. Pulse timing may be selected to hinder (e.g., measurably and / or substantially prevent) thermal overlap, to control solidification dynamics, and / or minimize (e.g., prevent) overheating above the threshold. The temporal resolution of the laser beam pulses may be optimized based at least in part on flange geometry, material absorption, and / or required coupling morphology.

[0188] In some embodiments, the laser operates with a defined pulse duration. The laser may operate as at most a nanosecond-class, at most a picosecond-class source, and / or at most a femtosecond-class source. In an example, the pulse duration is measured in nanoseconds (ns). The pulse duration may be at least about 5 ns, 8 ns, 10 ns, 15 ns, 30ns, 50ns, or 80ns. The pulse duration may be at most about 50 ns, 80ns, 100 ns, 150 ns, or 200 ns. The pulse duration may be of any value between the aforementioned values, e.g., from about 5 ns to about 200 ns. The pulse duration may govern the energy transfer rate into the weld zone. Shorter pulses, e.g., about 5 nanoseconds or 15 nanoseconds, may deliver concentrated energy within a constrained thermal window. Short pulse durations may promote rapid melting and / or directional solidification, with limited lateral heat diffusion. Temporal control of pulse width may enable weld depth precision and / or reduce grain coarsening near the interface. Pulse timing may be selected to match material response characteristics of the flange and / or the endplate.

[0189] In some embodiments, the coupling operation utilizes at least one laser. The laser can comprise Ytterbium as the active gain medium. The laser may operate in a single transverse mode. The laser may emit in the near-infrared regime with high efficiency and / or thermal stability. The emission characteristics may align with the absorption spectra of the material of at least one of the constraint portions to be coupled, e.g., stainless steel and / or aluminum. A single-mode laser may deliver a spatially coherent beam, e.g., with minimal divergence. The mode purity may support focused energy delivery over extended working distances. The combination of Ytterbium composition and single-mode structure may enable precise coupling spot (e.g., weld spot) formation across (e.g., constrained and / or metallic interfaces in the constraint system.

[0190] In some embodiments, the coupling (e.g., welding) process is implemented using a laser having a small FLS. The FLS of the small laser beam may define the energy footprint at the coupling (e.g., weld) site. A laser (e.g., within any configuration mentioned herein) may enable precise control of coupling initiation and / or termination. The defined optical and / or temporal properties may minimize unintended thermal exposure to battery components. The use of a small laser may improve safety for the operator, equipment, and / or cell assembly. The system size and / or electrical demand may be compatible with portable welding platforms. The small laser may reduce capital expenditure, e.g., by reducing (e.g., substantially avoiding)Atorney Docket No. 000456-0108-WO1 (ENX-0154.WO) high-capacity optics, intricate optical setups, lower grade power supplies, and / or beam isolation systems.

[0191] In some embodiments, the coupling strategy is modified with minimized (e.g., substantially without) requirement for alteration of the laser’s internal optical system. Coupling (e.g., welding and / or sintering) strategy attributes such as the pulse sequence, beam path, and / or spot progression pattern, may be adjusted. The coupling strategy attributes may comprise any of one or more laser beam properties such as disclosed herein. The adjustment may be controlled, e.g., manually and / or automatically such as by using the control system. In some embodiments, the adjustment is controlled (e.g., fully) automatically. The adjustment may be performed through software, control mechanism, and / or control scheme such as disclosed herein. The strategy-level modifications may reduce (e.g., substantially avoid) the cost and / or complexity, associated with redesigning the coupling sequence, and / or optical components associated with the coupling. The ability to refine coupling (e.g., weld and / or fusion) behavior with minimized (e.g., substantially without) laser hardware upgrade, modification, and / or replacement, may reduce tooling downtime reduce system integration overhead, reduce cost, simplify operations, or any combination thereof. The flexibility attributed to the coupling strategy modification, may allow optimization of coupling geometry and / or thermal input, across varying constraint designs. The constraint design may include endplate design, rigid portion design, flange design, or any combination thereof. The separation of optical setup design and / or coupling sequencing, may enable rapid iteration (e.g., agile variation) of coupling schemes during constraint system development and / or through different constraint systems.

[0192] In some embodiments, the laser source used for coupling the constraint components is not originally designed for metallurgical joining. The laser may be adapted from a system for material dicing, material ablation, material spallation, micromachining, and / or surface patterning. The underlying beam properties may be repurposed to achieve localized coupling (e.g., fusion) of constraint components, e.g., at flange-endplate interfaces. A reuse of a laser not purposed for the coupling procedure, may allow access to compact, precision-controlled systems (e.g., with high spatial resolution), and / or reduced cost. The optical parameters may be adjusted to match the thermal and / or geometric limitations of the constraint system. Repurposing available laser infrastructure may reduce system cost, reduce storage burden, reduce equipment footprint at the manufacturing facility, promote rapid deployment in development environments, and / or allow use in variable constraint systems. The reduction of equipment footprint at the manufacturing facility may be due to using the same laser(s) that are utilized for the building, for other operations.

[0193] In some embodiments, the laser beam comprises a requested spatial intensity profile (e.g., beam profile). The beam profile may be Gaussian, top-hat, and / or annular, with twoAtorney Docket No. 000456-0108-WO1 (ENX-0154.WO) symmetrical intensity peaks separated by a central minimum. An annular profile may correspond to a corona and / or doughnut-shaped footprint. The selected profile may influence the distribution of thermal energy across the coupling (e.g., weld) interface. A Gaussian profile may promote focused energy deposition at the beam center. A top-hat profile may deliver uniform energy across the entire spot diameter. An annular profile may reduce peak temperature at the center, for example, e.g., while enhancing edge melting and / or uniform temperature across a generated melt pool. The beam shape may be selected to match the geometry, thickness, and / or thermal boundary conditions, of the section(s) to be coupled such as the flange and / or the endplate. The beam shape may be selected to match the geometry, thickness, and / or thermal boundary, conditions of the constraint system, of the cell assembly disposed therein, and / or of the coupling section(s) - the endplate and / or the flange.

[0194] In some embodiments, at least one flange of the constraint system overlaps an edge region of the endplate. The overlap length may be at least about 10%, 20%, or 30% of the endplate height. The overlap length may be at most about 30%, 40%, or 50% of the endplate height. The overlap length may be of any value between the aforementioned values, e.g., from about 10% to about 50% of the endplate height. The overlap length may be such that the two opposing flanges coupled with an endplate are separated by a gap such that during the prescribed operation of the device (e.g., battery) a gap is maintained between the two opposing flange portions. The extent of the gap between the opposing flanges coupled with the endplate may or may not be (e.g., substantially) maintained during the prescribed operation of the device. The defined overlap between the flange and the endplate may establish a confined coupling region with predictable geometric boundaries and / or thermal boundaries. A partial engagement of the flange with the height of the endplate may allow uniform bonding by the coupling operation. The partial engagement may limit thermal dissipation (e.g., spread) such as towards the central region of the cell assembly. The overlap range of the flap with the endplate may be selected to enhance and / or maintain: coupling strength, reduce temperature variability during the coupling, promote cooling uniformity during the coupling, reduce deformation (e.g., warping) of the coupled component(s) during or as a consequence of the coupling, or any combination thereof. The deformation may comprise warping, balling, cracking, dislocating, or any combination thereof.

[0195] In some embodiments, the coupling strategy is selected to optimize process speed and / or precision, e.g., at minimized cost, labor, purchasing, facility footprint, maintenance, and / or setup time. During the coupling, the progression of the laser may follow a predefined path along the flange-endplate interface. The strategy may minimize optical component addons, and / or optical repositioning during the coupling operation. The laser beam steering may be performed using a gimbal, a galvanometer, a scanner, and / or a fixed-angle stage. The scanner may comprise a time-of-flight scanner, a phase shift scanner, or a triangulation laserAtorney Docket No. 000456-0108-WO1 (ENX-0154.WO) scanner. The laser scanner may comprise a stationary (e.g., terrestrial) scanner, a handheld scanner, or a mobile scanner. The laser may be installed in a laser gun. In some embodiments, the laser scanner is a stationary scanner. The reduction of optical movement may reduce coupling cycle time and / or alignment error. A continuous and / or semi-continuous, coupling progression may support high-throughput manufacturing. The optimized coupling path may enable consistent coupling spot spacing and / or thermal control across multiple coupling zones. The optimized coupling may minimize the idle time of the laser, e.g., the traveling time in which the laser does not perform a coupling operation such as welding.

[0196] While the coupling operation is described herein with a laser, a coupling rod (e.g., welding rod), or a plasma arc (e.g., generated by an electric arc), can be used instead, as applicable.

[0197] In some embodiments, the couplings (e.g., welds) along the flange-endplate interface are generated as a series of discrete spots arranged in a defined progression pattern. The coupling spots may be organized in a single arrangement or in multiple adjacent arrangements. The coupling spots may be organized in a single linear arrangement or in multiple adjacent linear arrangements. Each linear arrangement of weld spots may be referred to as a file. The spatial ordering of the coupling spots within and / or across files, may be defined to regulate coupling attributes. In an example, local heat accumulation, solidification timing, and / or mechanical uniformity, of the couplings are controlled by regulating the spatial ordering of the coupling spots. The coupling progression strategy may influence thermal overlap, cooling intervals, and / or geometric regularity, across the flange surface. A tailored sequencing of the spot generation order may promote coupling consistency in regions subject to constrained heat dissipation. The defined progression types disclosed herein may allow formation of structurally stable couplings across one or more flanges, such as with minimized (e.g., substantially without) thermal interference.

[0198] In some embodiments, the couplings (e.g., welds) are generated along a single file disposed on the flange. The single file may follow (e.g., be parallel to) an edge of the flange and / or of the endplate. The single file may be disposed between an edge of the flange and edge of the endplate, which flange and endplate the single file of couplings connects. The single file of couplings may comprise a sequence of discrete coupling (e.g., weld) spots arranged along a longitudinal direction parallel to the flange edge. The spot-to-spot distance may be defined to balance bonding continuity and / or thermal dissipation (e.g., thermal diffusion). A single file of the spots may serve as a reference geometry for validating coupling strength under controlled conditions. The single file configuration may reduce thermal interaction between adjacent rows and / or simplify optical beam steering. The single-file arrangement may be selected for initial calibration, thermal modeling, and / or coupling limitations, applications requiring minimal interface modification. The coupling limitations mayAtorney Docket No. 000456-0108-WO1 (ENX-0154.WO) comprise spatial limitations, geometric limitations, temporal limitations, thermal limitations, or any combination thereof. The spatial limitations and / or geometric limitations, may pertain to the space between the overlapping flange and endplate. The temporal limitations may pertain to reducing idle beam time during the coupling operation scheme. The thermal limitations may pertain to the thermal threshold requirements of the constraint system and / or cell assembly disposed therein.

[0199] In some embodiments, the couplings (e.g., welds) are distributed across multiple (e.g., linear) single files arranged in parallel on a flange to be coupled with the endplate. A multiplefile configuration may comprise at least two immediately spatially adjacent files extending along a shared longitudinal axis. The coupling spots of a first file may be aligned with the coupling spots of a second file. The lateral alignment may promote symmetric energy distribution across the flange width. The aligned spots may be on the same height axis normal to the lateral axis and normal to the longitudinal (e.g., stacking) axis of the cell assembly. The aligned spots may not be on the same height axis, e.g., they may be aligned in a staggered manner relative to each other. The use of multiple files may increase total bonded area, e.g., while substantially maintaining spatial regularity. The configuration may be selected to enhance mechanical strength and / or to reduce localized overheating at the coupling interface. The use of parallel files may permit independent adjustment of vertical and / or lateral spacing, between adjacent coupling spots. The spacing values may be selected based at least in part on flange thickness, one or more laser beam properties (e.g., beam FLS), and / or local thermal boundary conditions (e.g., of the cell assembly and / or constraint system). The defined separation may influence the rate of reaching a thermal equilibrium (e.g., cooling) and / or the extent of thermal overlap, during coupling (e.g., weld spot formation).

[0200] In some embodiments, the coupling spots of a first file are laterally aligned with the coupling spots of a second file positioned adjacent to the first. The alignment may occur along a direction parallel to the primary progression axis of the couplings. The aligned geometry may result in a columnar spot grid across the flange surface. The spatial arrangement described herein may facilitate symmetric thermal loading on opposing regions of the flange. The aligned files may allow simplified beam path programming and / or consistent optical pathing during high-speed coupling such as welding and / or sintering. The configuration may be selected to promote (e.g., ensure) uniform coupling spot surface FLS (e.g.., diameter) and / or controlled spot depth, along the coupling interface.

[0201] In some embodiments, at least two files of coupling spots couple a flange with an endplate. The coupling spots can be distributed laterally along the single file in an equidistance manner. The separation distance between spatially successive (e.g., spatially immediately adjacent) coupling spots in a file is referred to herein as the “intra-file distance” of the spots. The separation distance between spatially successive (e.g., spatially immediately adjacent)Atorney Docket No. 000456-0108-WO1 (ENX-0154.WO) files is referred to herein as the “inter-file distance.” Immediately spatially adjacent spots exclude a spot disposed therebetween. Immediately spatially adjacent files exclude a file disposed therebetween. The at least two files of coupling spots may each have coupling spots arranged in (e.g., substantially) the same equidistance manner, e.g., the intra-file distance of the spots is (e.g., substantially) the same in the at least two files. At least two immediately spatially adjacent files of the at least two files, may have their spots staggered with respect to each other, or aligned along the heigh axis with respect to each other. The at least two files may be distributed along a height of the flange in an equidistance manner, e.g., the inter-file distance is (e.g., substantially) the same in the flange(s) coupled with the endplate. The arrangement of the spots is (e.g., substantially) the same among the opposing endplates, the arrangement of the spots being within the file(s) and / or between the files. The intra-file distance of the spots may be (e.g., substantially) the same as the inter-file distance. The intra- file distance of the spots may be different than the inter-file distance. The intra-file distance of the spots may be larger, or smaller, than the inter-file distance. In an example, the intra-file distance of the spots is larger than the inter-file distance, e.g., within a flange and / or within an endplate. The inter-file distance may be at least about 5%, 10%, 15%, 20%, or 30% smaller than the intra-file distance of the spots. The inter-file distance may be at most about 20%, 25%, 30%, or 50% smaller than the intra-file distance of the spots. The inter-file distance may be smaller than the intra-file distance by any value between the aforementioned values, e.g., from about 5% to about 40%. The scheme of generating the coupling spots may be optimized to include a maximum number of coupling spots along a file to couple the flange with the endplate, e.g., to allow the manufactured device to operate according to its prescribed operating conditions, such as perform at least about 400 charge and discharge cycles with an anode comprising silicon with a content of at least about 40%. The spots on the endplate may be (e.g., substantially) homogenous, e.g., in terms of their FLS. The FLS (e.g., diameter) of the coupling spots of an endplate may be at least about 5%, 10%, 15%, 20%, 30%, 50%, or 80% smaller than the distance (e.g., inter-file and / or intra-file), e.g., resulting in a gap between successive spots along that distance. The FLS of the coupling spots of an endplate may be at least most about 20%, 25%, 30%, 50%, 70%, or 80% smaller than the distance (e.g., inter-file and / or intra-file). The FLS of the coupling spots may be smaller than the distance (e.g., interfile and / or intra-file) by any value between the aforementioned values, e.g., from about 5% to about 80%. The FLS (e.g., diameter) of the coupling spots of an endplate may be at least about 5%, 10%, 15%, 20%, 30%, 50%, or 80% larger than the distance (e.g., inter-file and / or intra-file), e.g., resulting in an overlap of successive spots along that distance. The FLS of the coupling spots of an endplate may be at least most about 20%, 25%, 30%, 50%, 70%, or 80% larger than the distance (e.g., inter-file and / or intra-file). The FLS of the coupling spots may be larger than the distance (e.g., inter-file and / or intra-file) by any value between theAtorney Docket No. 000456-0108-WO1 (ENX-0154.WO) aforementioned values, e.g., from about 5% to about 80%. The FLS (e.g., diameter) of the coupling spots of an endplate may be (e.g., substantially) as the distance (e.g., inter-file and / or intra-file), e.g., resulting in contacting spots along that distance.

[0202] In some embodiments, the prescribed operating conditions include one or more characteristics of the manufactured device (e.g., battery) such as disclosed herein. The maximum number of coupling spots may be generated with minimal heating of the constraint system and / or enclosure cell assembly therein. While the intra-file distance of the spots may be optimized to minimize direct thermal coupling while maximizing spot density along the file, thermal interference may still occur due to insufficient inter-file distance. The thermal interference occurring due to insufficient inter-file distance, may be reduced in a staggered spot configuration between successive files, as compared to a non-staggered arrangement of the spots along a height axis. The interplay between the intra-file distance of the spots and the inter-file distance, may allow residual heat from a coupling spot (e.g., weld) to influence successive spot(s) along the file and / or in successive file(s). To mitigate the thermal interference between successive spots, the temporal progression sequence of spot generation may be alternated, e.g., while maintaining the spatial positioning of the spots along an endplate. The temporal progression alternation of the spots may be within a file and / or among files. The alternate progression may promote (e.g., ensure) each newly generated coupling spot to thermally decouple from an adjacent spot, while (a) minimizing spot generation time and / or including maximal number of coupling spots along the endplate. The coupling spot generation strategy may (a) minimize cumulative thermal loading, (b) support formation of minimally defective (e.g., defect-free) coupling structures, (c) minimally affect thermally sensitive components of the manufactured device, (d) maximize production efficiency, (e) maximize throughput, (f) maximize reproducibility, (g) minimize equipment const, (h) minimize equipment footprint, (i) minimize labor, (j) maximize robustness of the manufactured device (e.g., constraint system thereof), (j) maximize robustness of the manufacturing process, or (k) any combination thereof.

[0203] In some embodiments, the coupling spot (e.g., welds) progression is configured to alternate between non-adjacent spot files (e.g., rows) across opposing flanges. The sequence may begin with a first file of coupling spots on a first flange, followed by a third file of coupling spots on a second flange. The progression may then return to a second file on the first flange and proceed to a fourth file on the second flange. The interleaved strategy described herein may introduce a temporal delay between coupling spots generated in adjacent regions along the height of the endplate. The time interval between successive coupling spots in thermally coupled zones may allow localized thermal equilibration (e.g., cooling) and / or phase stabilization of the resulting couplings (e.g., metallurgical phase stabilization). Alternating theAtorney Docket No. 000456-0108-WO1 (ENX-0154.WO) row order in the manner described herein may reduce cumulative heat accumulation and / or may promote uniform coupling microstructure across the generated coupling spots.

[0204] In some embodiments, the coupling (e.g., weld) spots in a first file are staggered relative to the weld spots in a second adjacent file. The staggered configuration may comprise offset positioning along the longitudinal direction of the flange. Each coupling spot in the second file may be located between two successive coupling spots in the first file. The arrangement described herein may increase the effective spacing between thermally adjacent spots and / or preserve interface coverage. The staggered pattern may promote uniform heat dissipation and / or minimize heat zone overlap between inter-file spots and between immediately spatially adjacent spots located in immediately spatially adjacent files. The staggered pattern may reduce localized thermal gradients, reduce thermal overlap, and / or minimize thermal effect on the thermally susceptible components of the manufactured device (e.g., in the constraint system and / or in the cell assembly). The spatial offset may distribute mechanical stress evenly across the coupled flange, e.g., during use of the device such as disclosed herein. The spatial offset of the spots among the immediately spatially adjacent files (e.g., in the flange and / or in the endplate) may improve fatigue resistance of the constraint system, e.g., during the prescribed use of the device (e.g., battery).

[0205] In some embodiments, the spacing between coupling spots within a flange is defined by two distinct directions. The directions may be a lateral direction and a height direction. The lateral distance between successive coupling spots may be greater than the corresponding height distance. The lateral direction may extend along the length of the flange. The height direction may extend across the flange, normal to the lateral direction. The differentiated spacing geometry may allow denser packing of coupling spots. The differentiated spacing geometry may substantially maintain sufficient lateral separation for thermal recovery at minimal time and / or minimal (e.g., detrimental and / or irreversible) thermal effect of the temperature susceptible components of the manufactured device. The spacing strategy described herein may reduce heat accumulation and / or minimize the (e.g., detrimental and / or irreversible) thermal effect of the temperature susceptible components of the manufactured device. The spacing strategy may facilitate (e.g., enable) higher coupling spot densities in limited surface regions.

[0206] In some embodiments, the weld coupling spots are generated using a defined spot progression pattern along one or more files. A sequential progression of coupling spot generation may involve generating coupling spots in a spatially and temporally sequential order along a single file. Such spot progression pattern may result in cumulative heat buildup along the spatial progression direction. The temporal and spatial sequential succession may increase the likelihood of thermal overlap between adjacent coupling spots. In alternative configurations, a zigzag progression may be used to alternate the coupling sequence betweenAtorney Docket No. 000456-0108-WO1 (ENX-0154.WO) two files of coupling spots. The zigzag pattern may be implemented between two opposing flanges coupled of an endplate. The zigzag pattern may be implemented within a flange comprising multiple files. The alternating sequence of spot generation among files may introduce temporal separation between immediately spatially adjacent (e.g., successive) coupling spots. The spatially alternating sequence of spot generation may promote heat diffusion. The zigzag strategy may allow for generation of higher spatial coupling densities, while minimizing the effect of heat accumulation during the manufacturing process of the couplings. The zigzag strategy may mitigate thermal interference across rows or flanges, e.g., while minimizing time of manufacturing such as minimizing idle beam time.

[0207] In some embodiments, the coupling spot progression follows a leapfrog-type sequence. A leapfrog progression may involve temporally sequential generation of coupling spots that are spatially non-sequential along the progression direction. The spatial displacement between consecutively generated spots may introduce intentional gaps, which gaps may later be filled with coupling spots to afford a succession of coupling spots. In this manner, the coupling spots may appear spatially successive, and are not temporally successively generated. The leapfrog pattern may increase the temporal interval between immediately adjacent couplings within a confined region. The delay in generation of spatially consecutive coupling spots may allow localized temperature dissipation (e.g., cooling) before thermal influence from a spatially neighboring spot is introduced. The leap-frog strategy may be selected to control cumulative heat flux, e.g., above the threshold of the heat sensitive components. The leapfrog strategy may be selected to stabilize solidification boundaries across the coupled interface. The leapfrog may be among spots in a single file and / or among files of spots in an endplate and / or in a flange.

[0208] In some embodiments, the coupling sequence follows a first leapfrog progression type arranged within a single file. The sequence may comprise the generation of a first weld spot, followed by a third weld spot, and then a second weld spot. The initial set of three welds may follow the order 1-3-2. The pattern may continue as 4-6-5, 7-9-8, and so forth, wherein each triad involves generating two non-adjacent welds before returning to the intermediate position. The numbers mentioned herein represent the number when a weld spot may be created. The temporal delay between welds in adjacent positions may allow partial cooling and / or phase stabilization, before thermal input is reapplied. The pattern may reduce cumulative temperature rise in spatially clustered weld zones. The sequencing strategy as disclosed herein may be selected to extend cooling intervals. The strategy may be selected to minimize (e.g., substantially avoid) reduction in total weld count and / or increase in lateral spacing.

[0209] In some embodiments, the spatial coupling spot progression follows a second leapfrog sequence within a single file. In a single file, the sequence may begin at a spatially located first spot, followed by a spatially located fourth spot, then a spatially located second spot, aAtorney Docket No. 000456-0108-WO1 (ENX-0154.WO) spatially located fifth spot, and then a spatially located third spot. The pattern may proceed as spatially locations 1-4-2-5-3-6 generated in a temporal succession, and continue with spatially located 9-7-10-8 generated in a temporal succession, or in a similar mirrored spatially located groupings that are temporally successively generated. The ordering may introduce long-range jumps before intermediate coupling spots are formed. The physical spacing may temporally separate adjacent coupling spots along the primary progression axis of a single file of coupling spots. The extended physical spacing between adjacent thermal zones may allow localized cooling. The extended physical spacing between adjacent thermal zones may maintain a denser coupling spot geometry as compared to generating spatial successive spots in a temporally successive manner along the file. The second leapfrog sequence may be selected to reduce heat interference along linear paths (e.g., file of spots). The second leapfrog sequence may promote uniform coupling (e.g., fusion) quality of the coupled constraint portions, e.g., flange and endplate.

[0210] In some embodiments, the coupling spot progression follows a third leapfrog sequence comprising interleaved spot generation across sub-segments of a single file. The sequence may initiate at physical spot 1 , followed by physical spot 5, then physical spot 3, and physical spot 7, which are temporally successively formed along a physical single file of coupling spots. The progression may continue with physical spot 2, then physical spot 6, followed by physical spot 4 and physical spot 8, which are temporally successively formed along a physical single file of coupling spots. The physical ordering mentioned along the single file, may be represented as 1-5-3-7-2-6-4-8, which are temporally successively formed. The sequence may extend further as 12-10-14-9-13-11-16 that are temporally successively formed along the single file of coupling spots, following the same interleaved logic. The spatial displacement between temporally adjacent couplings may allow heat dissipation before generating couplings in closely spaced regions, e.g., to minimize heat overlap of generated coupling zones. The progression may reduce local heat accumulation along any single sub-region of the flange. The third leapfrog strategy may be selected to balance thermal input across multiple fusion paths. The third leapfrog strategy may promote forming dense coupling spots along the endplate and / or flange - maximizing coupling density.

[0211] In some embodiments, the coupling spots are generated along a single file using a leapfrog progression strategy, e.g., any leapfrog strategy disclosed herein. The direction of progression may follow a (e.g., linear) path defined by the geometry of the flange. The temporal order of coupling spot generation may not correspond to their physical adjacency along the endplate (e.g., along the file). At least one (e.g., each) spot may be generated with a predefined spatial offset relative to the previous spot, e.g., intra-file spot distance. The leapfrog spacing may introduce localized cooling intervals between thermally adjacent positions along the same file. The progression pattern may reduce directional thermal buildupAtorney Docket No. 000456-0108-WO1 (ENX-0154.WO) along the coupling path, flange, and / or endplate. The progression strategy may facilitate tighter coupling spot spacing, e.g., inter-file distance of the spots and / or intra-file distance of the spots. The progression may minimize (e.g., substantially avoid) increasing the risk of thermal overlap and / or interface distortion. A choice between the different methodology may depend at least in part on the coupling methodology, on the material to be coupled, on the temperature threshold, on the extent of harm caused by exceeding the temperature threshold, on the throughput of the chosen methodology, on the robustness of the chosen methodology, or any combination thereof. In an example, a device having a lower temperature threshold (e.g., higher temperature susceptibility) may require greater spatial gap leapfrog methodology, than a device having a higher temperature threshold.

[0212] In some embodiments, the progression of coupling spot generation is distributed across several files of coupling spots arranged with respect to an endplate, e.g., on one or more flanges associated with that endplate. The spatial progression direction of couplings may span across files located within a single flange. The spatial progression direction may span between files positioned on separate opposing flanges coupled to the endplate. When applied within the same flange, the leapfrog sequence may alternate between at least two different files (e.g., rows) of couplings, e.g., to reduce localized heat buildup. The alternating leapfrog sequence may stagger thermal input along adjacent regions. When applied across different flanges, the progression may temporally separate coupling spot formation, e.g., at mirrored positions. The separation may allow thermal recovery before opposing couplings (e.g., welds) are generated. The temporal inter-file progression strategy may be selected to balance coupling (e.g., fusion) quality, minimize cross-zone interference, and / or maintain mechanical symmetry, across the endplate and / or across the constraint system.

[0213] In some embodiments, the strategy to generate the coupling spots supports selfregulated coupling process and / or localized thermal healing, at the flange-endplate interface. The defined temporal sequencing of coupling spot generation may limit the accumulation of residual stress during the coupling process, e.g., during melting and / or solidification. The temporal separation between thermally adjacent couplings (e.g., welds) may allow gradual dissipation of heat. The temporal separation may minimize grain coarsening and / or microstructural discontinuities. The spacing and / or coupling spot’s physical order may promote directional solidification. The spacing and / or physical order of the couplings may relieve transient strain gradients along the coupled interface. The resulting coupled structure may exhibit enhanced mechanical continuity and / or reduced initiation of interfacial cracks. The controlled overlap of thermal fields may facilitate localized reflow of under-fused regions. The controlled overlap may reduce (e.g., substantially prevent) inducing thermal shock. The controlled overlap of thermal fields may promote robust coupling, e.g., metallurgical bonding. The robust coupling may be during the lifetime of the prescribed use and / or lifetime of theAtorney Docket No. 000456-0108-WO1 (ENX-0154.WO) manufactured device, e.g., battery. The controlled overlap of thermal fields may (e.g.., substantially) preserve dimensional stability of the constraint system. The preservation of dimensional stability may be during the lifetime of the prescribed use and / or lifetime of the manufactured device, e.g., battery.

[0214] In some embodiments, a method is provided for fabricating a cell assembly (e.g., battery). The method may comprise at least one of (i) producing an electrode assembly, (ii) coupling the electrode assembly with the constraint system to form an electrode construct, (iii) assembling the electrode construct with an electrolyte mix into a battery enclosure (e.g., pouch), or (iv) any combination thereof. The electrode construct may comprise utilizing coupling methodology. The coupling methodology may be any of the ones disclosed herein, e.g., welding, fusing (e.g., sintering, or brazing), or any combination thereof. The coupling may comprise a metallurgical methodology utilized for coupling, e.g., using an energy beam (e.g., laser beam) mechanical pressure, and / or other localized energy (e.g., heat) source. The coupling may comprise utilization of a control system such as disclosed herein. Fabrication of the constraint system by coupling its components, may utilize a thermal management sequence of coupling spots. The operations of the method may be performed in any sequence. The method disclosed herein may be repeated any number of times, e.g., based on structural configuration, material property of the materials involved, and / or process feedback. The method may comprise a constraint structure in close proximity with, or operatively (e.g., physically) coupled with, an electrode assembly. The close proximity may be such that when the constraint portion is heated above a threshold, the temperature will affect the electrode assembly. The method may comprise producing an electrode assembly by stacking unit cells in a defined direction, with each unit cell comprising an anode separated by a gap from a respective cathode such as by a separator and / or spacer members. The method may comprise forming a battery enclosure. The method may comprise introducing the electrode assembly and / or an electrolyte into the enclosure. The method may comprise coupling a constraint system with the enclosure such as a can or a pouch. The coupling operation may be implemented by a laser welding operation. The welding sequence may be selected to hinder (e.g., measurably and / or substantially prevent) thermal damage to the enclosure and / or maintain stability of internal battery components. The internal battery components may comprise the cell assembly components, the electrolyte mix components, or any combination thereof. The introduction of the electrolyte mix to the cell assembly may be after generating the cell construct including the cell assembly coupled with the constraint system.

[0215] In some embodiments, an energy storage device comprises a set of battery cells enclosed within a casing structure. The battery cells may comprise alternating electrodes and counter electrodes separated by a gap comprising a separator. Each electrode may comprise a current collector that extends laterally beyond an edge of the separator by a tab. The tabsAtorney Docket No. 000456-0108-WO1 (ENX-0154.WO) of a given electrode type may extend in a common direction to facilitate electrical connection, e.g., by connecting with each other and / or with a busbar. The casing may comprise two opposing casing structures. The casing may comprise two end plates joined to enclose the set of battery cells. The structural configuration may support electrical isolation, dimensional stability, and / or modular packaging of the electrode stack.

[0216] Fig. 10 shows schematic example 1030 depicting edge portions of an energy storage device, (e.g., a battery). The device comprises battery cells including alternating structure of electrodes such 1031 and counter electrodes separated from each other by a gap such as 1032, e.g., comprising a separator. Each electrode type (e.g., each anode and each cathode) includes its respective current collector onto which active material is deposited (e.g., at one or at both opposing sides). The current collector of each anode type extends laterally by an extended portion, e.g., by a tab such as tab 1033. The tab of current collector portions of an electrode type, extend to the same lateral direction beyond an edge of the separator, which separator extends laterally beyond each of the electrode active material type. The set of cells is encased in a casing formed by two opposing casing portions 1037a and 1037b (e.g., rigid portions of the constraint system), and by two opposing end plates such as end plate 1038. The constraint system includes the casings, e.g., and may include an adhesive and / or a coating.

[0217] In some embodiments, a pair of flanges belonging to distinct constraint portions are coupled (e.g., welded) using a sequence of coupling (e.g., welding) spots arranged across s several rows. The flanges may be spaced by a lateral distance - a gap. The gap may be (e.g., substantially) fixed. The coupling spots may be distributed at a defined pitch. The spatial coupling sequence may span the lateral distance across several rows. The use of the several rows may be to reduce thermal overlap, to control thermal gradients, to lower expenses, to increase resolution of temperature change during - or as a consequence of - the coupling, or any combination thereof. The approach may support leapfrog and / or alternating progression patterns. The approach may manage heat input and / or promote interface stability. The coupling approach may generate spatially adjacent spots in a temporal distant manner. The coupling approach may generate spatially adjacent spots with minimal (e.g., with no) thermal overlap.

[0218] Fig. 11 illustrates an example 1100 comprising a first flange 1104 and a second flange 1106. The first flange 1104 and the second flange 1106 belong to two distinct rigid constraint portions laterally spaced from one another by a gap 1108. Each flange 1104 and 1106 may be joined with endplate 1108 at an opposing terminal region of a cell assembly. A plurality of coupling (e.g., weld) spots such as 1102a and 1102b, are disposed along the flanges 1104 and 1106, respectively. The plurality of coupling spots 1102a and 1102b are arranged in laterally aligned rows along the flange 1104 and 1106, respectively. A first couplings row (e.g.,Atorney Docket No. 000456-0108-WO1 (ENX-0154.WO) single file) R1 is disposed on flange 1104. The first couplings row R1 includes a row of the plurality of coupling spots such as 1102a. A second row of coupling spots (e.g., single file) R2 is disposed on flange 1106. The second row of coupling spots R2 includes the plurality of coupling spots such as 1102b. A height distance 1112 defines a dimension of the coupled structure illustrated in the example 1100. A lateral distance 1110 defines a length of each of the flanges 1104 and 1106. The length can be defined normal to the stacking axis of the cell stack disposed in the constraint system - cell stack not shown. The lateral distance 1110 and the height distance 1112 are determined based on the geometry of the constraint system and the design of the device (e.g., battery). The coupling approach spans the lateral distance 1110 by forming the plurality of coupling spots across the first row R1 of spots and the second row R2 of spots in a non-temporally successive sequence. The sequence can be configured to reduce heat accumulation. The sequence can be configured to allow temporal spacing between adjacent thermal events within the same flange (e.g., 1104 or 1106) and / or across adjacent flanges (e.g., 1104 and 1106). The arrangement of the plurality of coupling spots supports thermal decoupling and directional coupling spot progression strategies, such as leapfrog sequences applied to fixed spacing configurations.

[0219] In some embodiments, the coupling of an endplate to flanges is performed using one or more couplers. The coupler (also herein “coupling agent”) may comprise an energy beam. The coupling agent(s) may comprise a laser beam, an electron beam, a welding rod, a plasma beam, or a plurality thereof. In an example, the coupling may be generated by couplers. At least two of the couplers may progress in the same direction, e.g., parallel to each other. At least two of the couplers may progress in different (e.g., opposing) direction, e.g., parallel to each other. At least two of the couplers may progress in a concerted and / or coordinated manner. At least two of the couplers may progress in a (e.g., substantially) simultaneous manner. At least two of the couplers may progress in a non-simultaneous (e.g., sequential) manner.

[0220] In some embodiments, the coupling (e.g.., welding) sequence comprises forward, and backward coupling progression passes along multiple coupling spot files (e.g., rows). The spots may be disposed across two flanges separated by a lateral gap distance. Alternating directions may reduce thermal accumulation, promote consistent solidification across the flange-endplate interface, and / or reduce downtime of the coupling tool (e.g., laser).

[0221] Fig. 12 illustrates an example 1200 comprising a first flange 1204 and a second flange 1206. The first flange 1204 and the second flange 1206 belong to two distinct rigid constraint portions laterally spaced from one another. Each flange 1204 and 1206 may be joined to an endplate 1208 at an opposing terminal region of a cell assembly. A plurality of coupling (e.g., weld) spots 1202a and 1202b are disposed along the flanges 1204 and 1206, respectively. The plurality of coupling spots 1202a and 1202b are arranged in laterally aligned rows alongAtorney Docket No. 000456-0108-WO1 (ENX-0154.WO) the first flange and the second flange, respectively. A first coupling row R1 - a first single file of spots - is disposed on the first flange 1204. A second coupling row R2 - a second single file of spots - is disposed on the second flange 1206. The first coupling row R1 includes the plurality of coupling spots such as 1202a. The second coupling row R2 includes the plurality of coupling spots such as 1102b. A height distance 1212 defines a height dimension of the coupled structure illustrated in the example 1200. A lateral distance 1210 defines length of each of the flanges 1104 and 1106. The height and lateral length, can be defined normal to the stacking a six of a cell assembly disposed in the constraint system - cell assembly not shown. The lateral distance 1210 and the height distance 1212 are determined based on the geometry of the constraint system and the design of the device (e.g., battery). The coupling approach spans the lateral distance 1210 by forming the plurality of coupling spots 1202a and 1202b across coupling rows R1 and R2, e.g., in a non-successive sequence. The coupling progression may include a general forward direction 1214 and a general backward direction 1216. The forward direction 1214 may define a first pass of the coupling along one or both rows R1 and R2. The backward direction 1216 may define a subsequent pass of the coupling er retracing over the previously processed region or alternating to the adjacent coupling row. The use of the forward direction 1214 and the backward direction 1216 promotes inter-row cooling and / or minimizes idle time of the coupling apparatus, e.g., generating an energy beam such as a laser beam. The use of an opposite retracting direction promotes reduced idle time of the machine, speeds productivity, reduced calibration requirement of the coupling device, reduces maintenance of the coupling device, increases streamline of the coupling operation, reduces energy consumption utilized for unnecessary maneuvering of the coupling device (e.g., using a scanner), or any combination thereof. The use of an opposite retracting direction supports uniform thermal distribution along the constraint flanges at a minimized time, with minimal thermal effects on components of the cell construct such as temperature sensitive components. In some embodiments, a first coupler may generate the coupling spots in R1 such as by progressing along direction 1214, and another coupler may generate the coupling spots in R2 such as by progressing along direction 1216. In some embodiments, a first coupler may generate the coupling spots in R1 such as by progressing along direction 1214, and another coupler may generate the coupling spots in R2 such as by progressing along direction 1214. In some embodiments, a first coupler may generate the coupling spots in R1 such as by progressing along direction 1216, and another coupler may generate the coupling spots in R2 such as by progressing along direction 1216.

[0222] In some embodiments, a diagonal coupling spot generation progression is applied across single files. The files (e.g., rows) of spots involved with the temporally diagonal spot progression, can be associated with an endplate. The files (e.g., rows) of spots involved with the temporally diagonal spot progression, can be on a flange. The files (e.g., rows) of spotsAtorney Docket No. 000456-0108-WO1 (ENX-0154.WO) involved with the diagonal spot progression, can each be on a different flange. The temporally adjacent spots may be generated in a physically distant manner such that they are minimally distant from each other in a way to minimally cause a temperature effect on each other (e.g., generate a minimum heat affected zone overlap), while minimally straining the maneuvering system of the coupling device. Minimally straining the maneuvering system may comprise minimally straining the scanner of the energy beam. The coupling path may be designed such that calibration of the coupling device (e.g., laser beam) is minimized, e.g., minimize abrupt, sharp angled, and / or jittery movement. The movement of the coupling device may include ghost lines (e.g., air lines), such as to maintain smooth movement and minimized sharp movements. The diagonal pattern may increase spatial separation between adjacent coupling spots, e.g., to reduce thermal influence (e.g., and overlap) between two spots that are generated temporally adjacent. The coupling strategy may reduce thermal overlap of heat affected zones, promote inter-coupling cooling, and / or promote thermal uniformity across the constraint structure and / or within the cell assembly. In some embodiments, the heat affected zone is the zone heated when coupling spot is generated.

[0223] Fig. 13 illustrates an example 1300 comprising a first flange 1304 and a second flange 1306. The first flange 1304 and the second flange 1306 belong to two distinct rigid constraint portions laterally spaced from one another. Each flange 1304 and 1306 may be joined with an endplate 1308 at an opposing terminal region of a cell assembly (now shown). A plurality of coupling (e.g., weld) spots such as 1302a and 1302b are disposed along the flanges 1304 and 1306 respectively in two single files of spot, each associated with a flange. The spots are arranged in laterally aligned rows along the first flange and along the second flange, respectively. A first row R1 of couplings is disposed on the first flange 1304. A second row R2 of couplings is disposed on the second flange 1306. The first row R1 includes the plurality of coupling spots such as 1302a. The second row R2 includes the plurality of coupling spots such as 1302b. A height distance 1312 defines a dimension of the coupled structure illustrated in the example 1300. A lateral distance 1310 defines a lateral length of each of the flanges 1304 and 1306. The lateral length and / or height can be defined normal to the stacking axis of a cell assembly (not shown). The lateral distance 1310 and the height distance 1312 are determined based on the geometry of the constraint system and / or the design of the device (e.g., battery). The coupling strategy traverses between the first row R1 and the second row R2 in a diagonal inter-row progression. The diagonal inter-row progression defines a zigzag path, wherein each coupling event is followed by a subsequent coupling on the opposite flange and at a lateral offset location. The coupling path intersects the lateral distance 1310 at an acute angle and alternates from a first spot on R1 to a second spot on R2 that is positioned at a different height level. The subsequent coupling operation returns to R1 at a third spot further along the lateral direction. This traversal continues in an alternating pattern across the lateralAtorney Docket No. 000456-0108-WO1 (ENX-0154.WO) distance 1310. The diagonal movement separates each coupling event from its immediate predecessor by spatial distance and / or flange location. The interleaved sequencing illustrated in the example 1300 reduces cumulative thermal exposure within each flange. The interleaved sequencing provides additional time for localized cooling between successive couplings. The alternating directionality promotes a more uniform thermal gradient and / or reduces asymmetric distortion along the coupling interface. A forward direction 1314 defines a progression path of the coupler (e.g., laser beam) during a first pass along the diagonally staggered coupling sequence. A backward direction 1316 defines a return path retracing over the diagonal sequence or proceeding along an interleaved diagonal path. The forward direction 1314 traverses diagonally between alternating files and between alternating flanges, forming a staggered sequence of coupling spots along the height of the structure. The backward direction 1316 complements this sequence by retracing in a reverse zigzag pattern, depositing coupling spots at intermediate positions between those defined by the forward direction 1314. The combination of the forward direction 1314 and the backward direction 1316 of coupling spot generation, defines an interleaved progression that promotes thermal decoupling. The combination increases cooling intervals and / or enhances uniformity of coupling formation across the flange-endplate interface. While the example in Fig. 13 is illustrated for a single coupler (e.g., laser beam), in other embodiments, multiple couplers may be utilized. In some embodiments, a first coupler may generate the coupling spots in R1 such as by progressing along direction 1314, and another coupler may generate the coupling spots in R2 such as by progressing along direction 1316 or opposite thereto.

[0224] In some embodiments, a coupling sequencing strategy is selected based at least in part on thermal spacing between adjacent coupling spots, temperature threshold of temperature sensitive cell construct components, and proximity of those components to the endplate to be coupled with the flanges. The strategy may comprise a sequential pattern, a basic leapfrog pattern, an advanced interleaved pattern, a zigzag pattern, or any combination thereof. The pattern may define time intervals and spatial gaps between successive coupling spots. A less condensed heat-affected zone may result from increased separation between coupling spots in space and / or time. The strategy may promote improved thermal dissipation, structural integrity, and / or coupling uniformity across the constraint system.

[0225] Fig. 14 illustrates three examples 1400, 1430, and 1460 of coupling (e.g., weld) spot sequencing progression as a function of time and spatial distance, designating different leapfrog type progressions with increasing distance between heat affected zones. Each example represents a different sequence strategy comprising a set of coupling spot indices along a single file. The spatial sequence of coupling spots in each of these examples is generated in a non-sequential temporal manner. The temporal sequence generation of coupling spots in each of these examples is generated in a non-sequential spatial manner.Atorney Docket No. 000456-0108-WO1 (ENX-0154.WO)

[0226] In example 1400, the couplings are formed sequentially in a spatially sequential (e.g., and linear) order from 1 through 6. The spacing between coupling events is minimized. The progression illustrated in example 1400 results in the most condensed heat-affected zones among the three illustrated examples. A condensed thermal footprint may increase the likelihood of residual heat accumulation and / or thermal coupling, between adjacent couplings. A more condensed thermal footprint coupling spot generation methodology may be appropriate to a cell construct which has a higher temperature threshold. A more condensed thermal footprint coupling spot generation methodology may be appropriate to a cell construct which has components having a lower temperature susceptibility. In the example 1400, spot in spatial location #1 is generated first at time=1 , followed by generation of spot in spatial location #3 at time=2, followed by generation of spot in spatial location #2 at time=3, followed by generation of spot in spatial location #4 at time=4, followed by generation of spot in spatial location #6 at time=5, and followed by generation of spot in spatial location #5 at time=6. In the scheme 1400, the numbers designate the temporal sequence of 1-3-2-5-6-5 generating a spatially single file of six coupling spots.

[0227] In example 1430, the couplings follow a leapfrog progression of type having a larger distance between heat affected zones as compared to 1400. The leapfrog sequencing strategy of example 1430 introduces temporal spacing between spatially adjacent couplings. Compared to the example 1400, the heat-affected zones in the example 1430 are less condensed. The heat affected zones in the example 1430 promote partial cooling and / or thermal decoupling. The progression in example 1430 may have a better chance of reducing coupling distortion and improve solidification morphology, as compared to the methodology in 1400. In the scheme 1430, the numbers designate the temporal sequence of 1 -4-2-5- 3-6-8-7- 10-8 generating a spatially single file of ten coupling spots. In the example 1430, spot in spatial location #1 is generated first at time=1 , followed by generation of spot in spatial location #3 at time=2, followed by generation of spot in spatial location #5 at time=3, followed by generation of spot in spatial location #2 at time=4, followed by generation of spot in spatial location #4 at time=5, followed by generation of spot in spatial location #6 at time=6, followed by generation of spot in spatial location #8 at time=7, followed by generation of spot in spatial location #10 at time=8, followed by generation of spot in spatial location #7 at time=9, and followed by generation of spot in spatial location #9 at time=10.

[0228] In example 1460, the initial couplings are placed at non-adjacent indices to maximize spacing along the file. Later couplings fill intermediate regions in a second temporal sweep. The resulting pattern forms a staggered coupling schedule in the time and spatial domains. The heat-affected zones are less condensed than in example 1430. The sequence from the example 1460 allows maximal thermal relaxation, improved cooling intervals, and / or reducedAtorney Docket No. 000456-0108-WO1 (ENX-0154.WO) microstructural defects, as compared to 1430. Among the illustrated examples, example 1460 offers the greatest thermal dispersion and / or coupling quality enhancement. In the scheme 1460, the numbers designate the temporal sequence of 1-5-3-7-2-6-4-8-12-10-14-9-13-11-15 generating a spatially single file of ten coupling spots. In the example 1460, spot in spatial location #1 is generated first at time=1 , followed by generation of spot in spatial location #5 at time=2, followed by generation of spot in spatial location #3 at time=3, followed by generation of spot in spatial location #7 at time=4, followed by generation of spot in spatial location #2 at time=5, followed by generation of spot in spatial location #6 at time=6, followed by generation of spot in spatial location #4 at time=7, followed by generation of spot in spatial location #8 at time=8, followed by generation of spot in spatial location #12 at time=9, followed by generation of spot in spatial location #10 at time=10, followed by generation of spot in spatial location #14 at time=11 , followed by generation of spot in spatial location #9 at time=12, followed by generation of spot in spatial location #13 at time=13, followed by generation of spot in spatial location #11 at time=14, and followed by generation of spot in spatial location #15 at time=15 to optionally continue the sequence.

[0229] In some embodiments, the coupling spot sequence is structured as a temporally non- successive progression along a single flange to form a spatially successive file of spots. The sequence may delay successive thermal events, e.g., along the lateral direction and / or height direction of the flange. The timing of the coupling spot generation may reduce overlap of heat- affected zones and / or promote spatial heat decoupling between spots. The progression may support uniform coupling morphology. The progression may minimize residual thermal stress during high-density coupling operations.

[0230] Fig. 15 illustrates an example 1500 comprising a first flange 1504 and a second flange 1506. The first flange 1504 and the second flange 1506 belong to two distinct rigid constraint portions laterally spaced from one another by a gap along the height axis 1512. Each flange of the flanges 1504 and 1506 may be joined to endplate 1508 at an opposing terminal region of a cell assembly (not shown). A plurality of coupling (e.g., weld) spots such as 1502a and 1502b are disposed along the flanges 1504 and 1506, respectively. The spots are arranged in two laterally aligned rows along the first flange 1504 and the second flange 1506, respectively. A first row R1 is disposed on the first flange 1504. A second row R2 is disposed on the second flange 1506. The first row R1 includes the plurality of weld spots such as 1502a. The second spot row R2 includes the plurality of spots such as 1502b. A height distance 1512 defines a dimension of the coupled structure illustrated in the example 1500. A lateral distance 1510 defines a lateral length of each of the flanges 1504 and 1506. The lateral distance 1510 and the height distance 1512 are determined based on the geometry of the constraint system and / or the design of the device (e.g., battery). The coupling approach spans the lateralAtorney Docket No. 000456-0108-WO1 (ENX-0154.WO) distance 1510 by forming the plurality of coupling spots in the rows, including spots 1502a and 1502b, in a non-temporally successive leapfrog progression, the leapfrog succession being confined to a single flange. A forward direction 1514 defines a coupling sequence along the first flange 1504 following a temporal sequence pattern, e.g., 1-3-2-4-6-5. A backward direction 1516 may be used to return to the starting locations along flange 1506. For example, the forward direction 1514 is used to move the coupler (e.g., laser beam) from spot 1 to spot 3. The backward direction 1516 is used to move the welder back from spot 2 to spot 3. The coupling spots illustrated in the example 1500 are confined to a single flange per pass of the coupler. The number in each spot designates the temporal sequence of the coupler generating the coupling spot. The temporally non-successive intra-flange sequence promotes delayed thermal overlap between closely spaced coupling spots. The temporally non-successive sequence can facilitate and / or enhance thermal decoupling. The non-successive sequence reduces an effective overlap of heat-affected zones. In some embodiments, a first coupler may generate the coupling spots in R1 such as by progressing along direction 1514, and another coupler may generate the coupling spots in R2 such as by progressing along direction 1516, or opposite thereto. In some embodiments, a first coupler may generate the coupling spots in R1 such as by progressing along direction 1514, and another coupler may generate the coupling spots in R2 such as by progressing along direction 1514. In some embodiments, a first coupler may generate the coupling spots in R1 such as by progressing along direction 1516, and another coupler may generate the coupling spots in R2 such as by progressing along direction 1516.

[0231] In some embodiments, the coupling scheme configuration comprises four parallel rows of couplings disposed across a pair of opposing constraint flanges. The rows of spots may be grouped into two rows per flange. The weld rows are arranged to enable alternating weld sequences between non-adjacent rows. The row structure disclosed herein may promote extended thermal spacing, increased cooling intervals, and / or controlled heat distribution, during multi-pass coupling (e.g., welding) operations.

[0232] Fig. 16 illustrates an example 1600 comprising a first flange 1604 and a second flange 1606. The first flange 1604 and the second flange 1606 belong to two distinct rigid constraint portions laterally spaced from one another. Each flange may be joined to an endplate 1608 at a terminal region of a cell assembly (not shown). A plurality of coupling (e.g., weld) spots such as 1602a and 1602b, are disposed on the first flange 1604 and the second flange 1606, respectively. The first flange 1604 comprises two coupling spots (e.g., welding) rows R1 and R2. The second flange 1606 comprises two coupling spots (e.g., welding) rows R3 and R4. The rows R1 through R4 extend laterally along each flange and are arranged in parallel to each other and to an edge of the flange. A height distance 1612 defines a dimension of the structure. A lateral distance 1610 defines the length of each flange. Each row includes aAtorney Docket No. 000456-0108-WO1 (ENX-0154.WO) plurality of coupling spots arranged in linear lateral alignment. The layout shown in Fig. 16 enables multi-row coupling spot sequencing across flanges. In some configurations, the sequence alternates between non-adjacent rows across opposing flanges, e.g., from R1 to R3 or from R2 to R4. The inter-flange pairing mentioned herein increases the physical spacing between consecutive welds. The inter-flange pairing may reduce the overlap of heat affected zones between rows (e.g., single files) of coupling spots, and / or introduce a cooling time between successive thermal events. In some embodiments, the use of offset coupling progression of single file of coupling spots generation, reduces heat accumulation, limit heat- affected zone overlap, reduces a risk of damaging the heat susceptible components of the cell-construct, and / or supports controlled solidification of the couplings, e.g., at each coupling spot site. The four-row architecture may enable adaptive strategies such as row staggering, leapfrog timing, and / or alternating lateral displacement, to balance weld density and thermal diffusion. The four-row architecture may enable robust coupling of the constraint portions while using a low power and / or low cost, coupling tool (e.g., laser). The four-row architecture may minimize harm to the cell construct as a result of the coupling process.

[0233] In some embodiments, the structure comprises four rows of couplings (e.g., welds) distributed across two opposing constraint flanges. The progression of coupling spots generation may alternate between non-adjacent rows disposed on different flanges during a first directional pass. A second directional pass may follow interleaved intermediate rows in reverse order. The bidirectional and inter-flange progression disclosed may minimize idle time of the coupler (e.g., energy beam such as laser), temporal spacing between adjacent couplings, increase thermal decoupling, increase the integrity of the cell-construct, and / or support uniformity, in coupling spot formation across the flange-endplate interface.

[0234] Fig. 17 illustrates an example 1700 comprising a first flange 1704 and a second flange 1706 disposed above endplate 1708. The first flange 1704 and the second flange 1706 belong to two distinct rigid constraint portions laterally spaced from one another by a gap. Each flange of flanges 1704 and 1706 may be joined to an endplate such as 1708 at a terminal region of an electrochemical cell assembly (not shown). A plurality of coupling (e.g., weld) spots such as spots 1702a and 1702b, are disposed along first flange 1704 and second flange 1706, respectively. The spots are organized into two rows in each flange: spot rows R1 and R2 on first flange 1704, and spot rows R3 and R4 on second flange 1706. A lateral distance 1710 defines a length of each of the flanges 1704 and 1706. A height distance 1712 defines an extent of the coupled constraint structure. A forward direction 1714 defines a possible generation progression path of the coupling spots, e.g., across first row R1 and third row R3. A backward direction 1716 defines a possible return progression direction path, e.g., across second row R2 and fourth row R4. The coupling spot generation sequence can alternate between the rows, e.g., between the first flange 1704 and the second flange 1706. The pairingAtorney Docket No. 000456-0108-WO1 (ENX-0154.WO) of paths may be at least in part by pairing non-adjacent rows (R1 with R3 and R2 with R4) and assigning each pair a different path direction. Such inter-flange alternating progression scheme of coupling spot generation can increase the thermal spacing between successive couplings (e.g., welds). The configuration may promote directional dissipation of heat across non-contiguous rows. The coordinated progression defined by a forward direction 1714 and a backward direction 1716, can enable high-density couplings deposition with minimal thermal overlap and / or minimal thermal burden experienced by heat sensitive components of the cell construct. The coordinated progression can enable enhanced cooling intervals between successive coupling spots and / or coupling spot rows. The structural configuration illustrated in the example 1700 can support thermally efficient multi-row coupling (e.g., welding) across opposing constraint flanges. In some embodiments, multiple couplers (e.g., coupling agents such as laser beams) may operate to generate rows of coupling spots on the same endplate. In some embodiments, multiple couplers may operate to generate rows R1-R4. At least two of spot rows R1-R4 may be generated by the same coupler. At least two of spot rows R1-R4 may be generated by different couplers. At least two of the couplers may propagate in the same direction. At least two of the couplers may propagate in different directions. At least two of the couplers may generate coupling spots on the same flange. At least two of the couplers may generate coupling spots on different flanges. In some examples, a first coupler generates the coupling spots in R1 such as by progressing along direction 1714, and another coupler generates the coupling spots in R4 such as by progressing along direction 1716. In some examples, a first coupler generates the coupling spots in R1 such as by progressing along direction 1714, and another coupler generates the coupling spots in R2 such as by progressing along direction 1714. In some examples, a first coupler generates the coupling spots in R1 such as by progressing along direction 1716, and another coupler generates the coupling spots in R3 such as by progressing along direction 1716.

[0235] In some embodiments, a method of fabricating a secondary battery comprises producing a constraint coupled by a coupling methodology such as disclosed herein, e.g., by laser welding. The method may comprise (i) providing an electrode assembly (ii) coupling a constraint system with the electrode assembly by minimally (e.g., without detrimentally) disturbing the integrity of the cell construct (e.g., the temperature sensitive components thereof), or (iii) a combination thereof. The method may be implemented using a welding control system such as disclosed herein, e.g., comprising hardware circuitry and / or machine-readable instruction sets. The coupling of the constraint system with the electrode assembly by minimally (e.g., without detrimentally) disturbing the integrity of the cell construct, is such that the manufactured device (e.g., battery) functions according to its requested and / or prescribed operation, e.g., under the prescribed operating conditions such as disclosed herein.Atorney Docket No. 000456-0108-WO1 (ENX-0154.WO)

[0236] Fig. 18 illustrates an example flowchart for a method of fabricating a cell construct, the method comprising providing an electrode assembly having cell temperature susceptible component(s) in block 1802; arranging the electrode assembly relative to the constraint system components to be coupled, the constraint system optionally having constraint temperature susceptible component(s) in block 1804; and in block 1806, coupling the components of the constraint system while the cell assembly is disposed in an interior space of the constraint system, to generate a cell construct at least in part by generating coupling spots in a sequence configured to minimize thermal effect on the temperature susceptible component(s) of the cell construct, the coupling being at a temperature substantially higher than the temperature threshold(s) of the temperature susceptible components of the constraint and / or of the cell assembly, and the temperature susceptible component(s) of the cell construct including the temperature cell susceptible component(s) and / or on the constraint temperature susceptive component(s). The coupling spot (e.g., welding spot) sequence is selected to hinder (e.g., measurably and / or substantially prevent) thermal damage to the cell construct during coupling. The method may be implemented using a control system such as disclosed herein, e.g., comprising hardware circuitry and / or machine-readable instruction sets. The substantially higher temperature may be at least about 3*, 5*, 7*, 10*, 15*, 20*, 25*, or 30* higher temperature. The substantially higher temperature may be higher by any multiplication value between the aforementioned valued, e.g., from about 5* to about 30*, or from about 5* to about 15*. The symbol “*” designates the mathematical operation of “times,” a.k.a. “multiplication.”

[0237] In some embodiments, methodologies disclosed herein provide for controlling a coupling (e.g., weld) generation strategy for coupling constraint rigid body to the endplates in a cell assembly. The method may comprise at least one of (i) initiating a coupling spot control sequence, (ii) evaluating thermal and geometric parameters of the cell assembly and constraint system components (e.g., to be coupled), (iii) selecting a coupler (e.g., energy beam) power and progression strategy of spot generation, (iv) applying corrective modification to coupling spot (e.g., weld) inputs, (v) repeating one or more operations based on updated conditions (e.g., using a feedback loop), (vi) finalizing the coupling interface, or (vii) any combination thereof. The operations of the method may be performed in any sequence. The operations of the method may be repeated any number of times based on process conditions and / or control feedback. The method may comprise initiating a coupling spot (e.g., weld) control sequence and verifying alignment of the constraint structure with a defined coupling interface. The method may comprise evaluating parameters of the constraint flanges, endplates, cell assembly components, adhesive elements, or any combination thereof. The cell assembly components can comprise current collectors, busbars, active material(s), separators, spacer member, or any other cell assembly components disclosed herein. TheAtorney Docket No. 000456-0108-WO1 (ENX-0154.WO) evaluated parameters may include mechanical, physical, geometric, and / or chemical parameters. The evaluated parameters may include thermal and / or geometric parameters. The method may comprise selecting a coupler power and / or progression strategy. The selection may be based on simulation outputs, predefined control logic, and / or materialspecific profiles. The method may comprise applying a corrective modification to one or more coupling (e.g., weld) parameters. The correction may be applied based on measured and / or inferred deviation from target coupling outcomes. The method may comprise repeating one or more operations to refine the coupling strategy and / or update the input parameters. The method may terminate by finalizing the coupling interface and / or logging system outputs.

[0238] Fig. 19 shows a method for coupling (e.g., welding) constraint structure components with a cell assembly to generate a cell construct. The method comprises initiating the coupling control sequence and verify alignment of the constraint structure with a coupling (e.g., welding) interface in block 1902; evaluating thermal properties and geometric parameters of the cell assembly and constraint system components selecting a weld power and spot progression strategy based at least in part on the evaluation in block 1904; selecting a power scheme for the coupler (e.g., laser beam) and spot progression strategy based at least in part on the evaluation in block 1906; and applying corrective modification of the coupling spot inputs based on deviations from predefined target conditions, in block 1908. Feedback loop 1911 links block 1904 to block 1906 for iterative refinement of coupling parameter selection. Feedback loop 1912 links block 1908 to block 1904 for corrective modification of inputs. The operations illustrated in Fig. 19 may be performed in the order shown, in a different sequence, or in any combination thereof, as applicable.

[0239] In some embodiments, the energy manipulation device (e.g., battery) is utilized for providing energy to electrical devices (also referred to herein as “target device”). The target device(s) may include smartphone, tablet, wearable electronics (watches, glasses, health tracks), power bank (e.g., for mobile devices), micro portable devices (drones, cameras, smart card), mobile Wi-Fi, Bluetooth headset, smart home related device (loTs), electric toothbrushes, precision grooming tools, small-scale gardening equipment, (e.g., service) robots, (e.g., compact) medical such as chest compression, cosmetics, (e.g., compact) exercise, other wellness devices, learning tools, UAVs (drones) such as for short distance, e.g., racing, short distance, and military drones, torpedoes, and missiles. The target device may comprise a vehicle. The vehicle may comprise a ship, a spacecraft, an airplane, a helicopter, a spaceship, a train, a car, or a truck. The target device may comprise industrial equipment, online banking 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 combinationAtorney Docket No. 000456-0108-WO1 (ENX-0154.WO) thereof. The energy manipulation device (e.g., battery) may be utilized for any battery powered electronic product. The robots may be servicing 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 can comprise a 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., an MP3 player. The drone may be an underwater drone and / or an aerial drone. The target device may comprise a cellular phone. The target device may be a portable device, a notebook computer, an electric toy, or an electric tool. The vehicle can be a pure electric vehicle, a hybrid electric vehicle or a range-extended vehicle. The spacecraft may include airplanes, rockets, space planes, or a spaceship. The electric toy can comprise a fixed toy, or a mobile toy. The toy may comprise a game machine, or an electric vehicular toy. The vehicular toy may comprise any vehicle type disclosed herein. The power tools may comprise metal cutting tools, grinding tools, assembly tools, or railroad tools. The power tools may comprise electric drills, electric grinders, electric wrenches, electric screwdrivers, electric hammers, impact drills, concrete shakers, or electric planers.

[0240] In some embodiments, the device is manufactured. The device can be fabricated (e.g., fabricated). The environment may or may not be an a...

Claims

Atorney Docket No. 000456-0108-WO1 (ENX-0154.WO)CLAIMSWhat is claimed is:

1. A device for energy manipulation of an electrochemical cell assembly, the device comprising: a cell assembly being the electrochemical cell assembly comprising an electrode separated from a counter electrode by a gap, the cell assembly comprising at least one temperature susceptible material above a temperature threshold; a first component of a constraint system contacting the cell assembly; and a second component of a constraint system contacting the cell assembly, the second component being coupled with the first component using couplings generated at a coupling temperature above the temperature threshold, the coupling temperature resulting in harm to a prescribed operation of the device, the second component being coupled with the first component in a manner indicative of the cell assembly being in contact with the first component and / or second component during the coupling, the device being unharmed by the coupling.

2. The device of claim 1 , wherein the thickness of the first component and / or second component is at most about 50 micrometers (pm).

3. The device of claim 1, wherein the cell assembly comprises at least about 50 unit cells.

4. The device of claim 1, wherein the couplings are indicative of being generated by at least one energy beam having (a) a low power of at most about 100 watts and / or (b) footprint having a small fundamental length scale of at most about 500 micrometers.

5. The device of claim 1, wherein the couplings are spaced apart on a single file of couplings along a lateral axis of the first component at an intra-file distance, wherein the couplings comprise spots arranged in single files parallel to each other; wherein a first set of the single files that are successive are distanced from each other by a first inter-file distance, the intra-file distance being larger than the first inter-file distance.

6. The device of claim 1, wherein the couplings are configured to withstand pressure variations of at least about 100 pounds per square inch (psi); and wherein the couplings are configured to withstand pressure variations repeatedly over the prescribed operation of the device.

7. The device of claim 1, wherein the at least one temperature susceptible material is devoid of observable, measurable and / or substantial defects to an extent that the harm results during a prescribed lifetime of the device in the prescribed operation of the device.

8. The device of claim 1 , wherein the manner indicative of the cell assembly being in contact with the first component and / or second component during the coupling comprises a geometric configuration of the cell assembly with respect to the first component and the second component.Atorney Docket No. 000456-0108-WO1 (ENX-0154.WO)9. The device of claim 1, wherein a prescribed operation of the device comprises cycling between charge and discharged state of the cell assembly.

10. The device of claim 1, wherein the couplings are metallurgical.

11. The device of claim 1, wherein the gap comprises a separator configured to allow separation of electrical change, and transfer of charge carriers therethrough, the at least one temperature susceptible material comprising the separator.

12. The device of claim 1, wherein the cell assembly comprises spacer members configured to support an electrode current collector that is part of the electrode, the at least one temperature susceptible material comprising the spacer members.

13. The device of claim 1, wherein the electrode and the counter electrode are stacked along a stacking axis, the first component comprising an endplate disposed at a distal end of the cell assembly, the endplate being stacked along the stacking axis.

14. The device of claim 1, wherein the electrode and the counter electrode are stacked along a stacking axis; wherein the second component comprises an rigid portion having a main body and a flange at a distal end of the main body, the main body being disposed parallel to the stacking axis, and the flange being disposed perpendicular to the stacking axis.

15. The device of claim 1, wherein the energy manipulation device comprises a rechargeable battery.

16. The device of claim 1, wherein the energy manipulation device comprises a lithium-ion battery.

17. The device of claim 1, wherein the electrode comprises silicon.

18. The device of claim 1, wherein the harm is at least in part to the at least in part to the at least one temperature susceptible material of the cell assembly.

19. The device of claim 1, wherein the temperature threshold is a first temperature threshold; and wherein the constraint system comprises one or more temperature susceptible materials above a second temperature threshold, the coupling temperature being above the temperature threshold, the coupling temperature resulting in harm to the one or more temperature susceptible materials.

20. The device of claim 1, wherein the couplings are irreversible under a prescribed operating conditions of the device.

21. A method comprising: (a) providing the device of any of claims 1 to 20; and (b) manufacturing, testing, buffering, storing, transporting, and / or using the device for the energy manipulation.

22. An apparatus for using the device of any of claims 1 to 20, the apparatus comprises: at least one controller configured for (a) operatively couple with at least one mechanism andAtorney Docket No. 000456-0108-WO1 (ENX-0154.WO) with the device; and (b) executing, or directing the at least one mechanism to execute, one or more operations associated with use of the device.

23. One or more non-transitory computer readable media comprising program instruction physically inscribed thereon, the program instructions, when read by one or more processors, are configured to (I) execute, or direct execution of, one or more operations associated with use of the device of any of claims 1 to 20, and (II) the one or more operations comprising directing at least one component to execute the one or more operations, the one or more processors being configured to operatively couple with the at least one component.

24. An apparatus for fabricating the device of any of claims 1 to 20, the apparatus comprising: at least one controller configured for (a) operatively coupling with at least one mechanism; and (b) executing, or directing the at least one mechanism to execute, one or more operations associated with fabrication of the device.

25. One or more non-transitory computer readable media comprising program instruction physically inscribed thereon, the program instructions, when read by one or more processors, are configured to (I) execute, or direct execution of, one or more operations associated with fabrication of the device of any of claims 1 to 20, and (II) the one or more operations comprising directing at least one component to execute the one or more operations, the one or more processors being configured to operatively coupe with the at least one component.

26. A method of fabricating the device of any of claims 1 to 20, the method comprising: executing one or more operations to fabricate the device.

27. A method of fabricating an energy manipulation device, the method comprising: (a) providing a cell assembly comprising an electrode separated from a counter electrode by a gap, the cell assembly comprising at least one temperature susceptible material above a temperature threshold, the cell assembly being an electrochemical cell assembly, (b) contacting the cell assembly with a first component of a constraint system and with a second component of the constraint system, the contacting being at least in part for coupling of the first component with the second component, and (c) utilizing a coupling agent to couple the first component with the second component at a coupling temperature above the temperature threshold, the coupling temperature resulting in harm to a prescribed operation of the device, the cell assembly being unharmed by the coupling, the coupling agent generating couplings that couple the first component with the second component.

28. The method of claim 27, wherein utilizing the coupling agent in a way such that the at least one temperature susceptible material will not experience a temperature above the temperature threshold to an extend to cause the harm, the coupling agent being configuredAtorney Docket No. 000456-0108-WO1 (ENX-0154.WO) to increase the temperature of the first component and of the second component to generate the coupling.

29. The method of claim 27, wherein the thickness of the first component and / or second component is at most about 150 micrometers (pm).

30. The method of claim 27, wherein utilizing the coupling agent to couple the first component with the second component is such that the at least one temperature susceptible material will not experience a temperature above a temperature threshold.

31. The method of claim 27, wherein utilizing the coupling agent comprises utilizing a progression scheme of generating the couplings such that the cell assembly and / or the second component, does not exceed the temperature threshold.

32. The method of claim 27, wherein utilizing the coupling agent comprises utilizing a progression scheme of generating the couplings such that the cell assembly and / or the second component, does not exceed the temperature threshold.

33. The method of claim 27, wherein utilizing the coupling agent is in an atmosphere comprising at least one reactive species at a concentration lower than in an ambient environment, the at least one reactive species being configured to, during the coupling, react with (a) one or more components of the cell assembly and / or (b) one or more components of the constraint system.

34. The method of claim 27, wherein the cell assembly comprises at least about 50 unit cells.

35. The method of claim 27, wherein coupling agent comprises at least one energy beam having (a) a low power of at most about 100 watts and / or (b) footprint having a small fundamental length scale of at most about 500 micrometers.

36. The method of claim 27, wherein the couplings are generated such that they are spaced apart on a single file of couplings along a lateral axis of the first component at an intra-file distance, wherein the couplings comprise spots arranged in single files parallel to each other; wherein a first set of the single files that are successive are distanced from each other by a first inter-file distance, the intra-file distance being larger than the first inter-file distance.

37. The method of claim 27, wherein generating the couplings is such that they withstand pressure variations of at least about 100 pounds per square inch (psi), 200psi, 450psi, or 1000psi; wherein the couplings are configured to withstand pressure variations repeatedly over the prescribed operation of the device.

38. The method of claim 27, wherein the manner indicative of the cell assembly being in contact with the first component and / or second component during the coupling comprises a geometric configuration of the cell assembly with respect to the first component and the second component.Atorney Docket No. 000456-0108-WO1 (ENX-0154.WO)39. The method of claim 27, wherein (a) the first component is an endplate integrated with the cell assembly, (b) the second component comprises an adhesive adhering to the cell assembly, (c) the second component comprises opposing rigid bodies enclosing the cell assembly.

40. The device of claim 1, wherein a prescribed operation of the device comprises cycling between charge and discharged state of the cell assembly.

41. The method of claim 27, wherein the couplings are metallurgical.

42. The method of claim 27, wherein the gap comprises a separator configured to allow separation of electrical change, and transfer of charge carriers therethrough, the at least one temperature susceptible material comprising the separator.

43. The method of claim 27, wherein the cell assembly comprises spacer members configured to support an electrode current collector that is part of the electrode, the at least one temperature susceptible material comprising the spacer members.

44. The method of claim 27, wherein the electrode and the counter electrode are stacked along a stacking axis, the first component comprising an endplate disposed at a distal end of the cell assembly, the endplate being stacked along the stacking axis.

45. The method of claim 27, wherein the electrode and the counter electrode are stacked along a stacking axis; wherein the second component comprises an rigid portion having a main body and a flange at a distal end of the main body, the main body being disposed parallel to the stacking axis, and the flange being disposed perpendicular to the stacking axis.

46. The method of claim 27, wherein the energy manipulation device comprises a rechargeable battery.

47. The method of claim 27, wherein the energy manipulation device comprises a lithium-ion battery.

48. The method of claim 27, wherein the electrode comprises silicon.

49. The method of claim 27, wherein the harm is at least in part to the at least in part to the at least one temperature susceptible material of the cell assembly.

50. The method of claim 27, wherein the temperature threshold is a first temperature threshold; and wherein the constraint system comprises one or more temperature susceptible materials above a second temperature threshold, the coupling temperature being above the temperature threshold, the coupling temperature resulting in harm to the one or more temperature susceptible materials.

51. The method of claim 27, wherein the couplings are generated such that the coupling is irreversible under a prescribed operating conditions of the device.Attorney Docket No. 000456-0108-WO1 (ENX-0154.WO)52. The method of claim 27, wherein fabrication of the energy manipulation device comprises manufacturing.

53. The method of claim 27, further comprising testing, buffering, storing, transporting, and / or using the device for the energy manipulation.

54. An apparatus for of fabricating an energy manipulation device, the apparatus comprises: at least one controller configured for (a) operatively couple with at least one mechanism; and (b) executing, or directing the at least one mechanism to execute, one or more operations of the method of any of claims 27 to 53.

55. One or more non-transitory computer readable media comprising program instruction physically inscribed thereon, the program instructions, when read by one or more processors, are configured to (I) execute, or direct execution of, the method of any of claims 27 to 53; and (II) the one or more operations comprising directing at least one component to execute the method, the one or more processors being configured to operatively couple with the at least one component.

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