Degassing apparatus for battery cells

Abstract

Implementations of the present disclosure generally relate to apparatuses and methods to remove gases from batteries.

Description

DEGASSING APPARATUS FOR BATTERY CELLSCLAIM TO PRIORITY

[0001] This patent application claims the benefit of priority to U.S. Provisional Patent Application Serial No. 63 / 683,096, filed August 14, 2024, which is incorporated by reference herein in its entirety.TECHNICAL FIELD

[0002] Implementations of the present disclosure generally relate to apparatuses and methods to remove gases from batteries.BACKGROUND

[0003] Batteries, and in particular, lithium-ion batteries, are known to evolve gaseous byproducts during operation at various points during their lifetime. For example, after cell assembly and when charged for the first time, during a process commonly known as “formation”, lithium-ion batteries generate gaseous compounds from the decomposition of electrolyte at both the anode and cathode, the compositions of which depend on the electrolyte formulation. Such byproducts typically include hydrogen, carbon dioxide, carbon monoxide, ethylene, ethane, and methane. To remove these gaseous byproducts from the cell after formation, a “degassing procedure” can be performed. The manifestation of this process depends on the specific battery cell format. For pouch cell formats, incomplete degassing can result in battery cell swelling, which compromises safety and ease of packaging. For other, “hard-case” cell formats, such as cylindrical and prismatic battery cells, degassing can be performed to minimize compromising the mechanical integrity of the casing. In prismatic cells, in particular, where the ratio of cell electrode area and electrolyte volume to cell case area is high, removing gaseous byproducts after formation is advantageous to improve cell reliability.SUMMARY

[0004] Processes, devices, methods, and systems of the present disclosure are directed to implementations for the removal of gaseous byproducts from batteries during manufacturing. In one or more examples, a method comprises providing a battery enclosure that includes a casing.The battery enclosure can include a first section and a second section. A plurality of lithium-ion battery electrodes can be located in the first section and a port can be located on a portion of the casing that corresponds to the second section. The method can also include performing an initial charging process for the plurality of lithium-ion battery electrodes. The initial charging process can cause formation of one or more gases within the battery enclosure. In addition, the method can include causing the one or more gases to be released out of the battery enclosure through the port in response to a pressure within the battery enclosure being at least a threshold pressure. Further, the method can include after completion of the initial charging process and after the pressure within the battery enclosure is less than the threshold pressure, modifying the battery enclosure to produce a lithium-ion battery package.

[0005] In addition, an apparatus can comprise a pouch cell battery package. The pouch cell battery package can include a casing forming an outer shell of the battery package. A port can be disposed within the casing and the port can be configured to release gas within the casing in response to a pressure within the casing being at least a threshold pressure. A plurality of battery electrodes can be disposed within the battery package.

[0006] Further, an apparatus can comprise a prismatic cell battery package. The prismatic battery package can include a casing forming an outer shell of the battery package. The casing can include a battery enclosure and a top secured to the battery enclosure. Additionally, a valve can be disposed within the top of the casing and the valve can be configured to release gas within the casing in response to a pressure within the casing being at least a threshold pressure. A plurality of battery electrodes can be disposed within the battery package.BRIEF DESCRIPTION OF THE DRAWINGS

[0007] Figure 1 illustrates an example process to remove one or more gases from a pouch cell that includes a battery stack, in accordance with one or more example implementations.

[0008] Figure 2 illustrates an example process to remove one or more gases from a prismatic cell that includes a battery stack, in accordance with one or more example implementations.

[0009] Figure 3 includes a flow diagram of an example method to remove one or more gases from a battery cell that includes a battery stack, in accordance with one or more example implementations.DETAILED DESCRIPTION

[0010] In pouch cells, degassing is commonly performed by first physically creating a perforation in the pouch casing, through which gases are allowed to escape and through which the cell innards can be exposed to a vacuum, which evacuates residual gases and promotes wetting of electrolyte throughout the porosity of the cell. This perforation is then subsequently sealed to prevent air ingress into the pouch cell during operation. This degassing process is tedious and timeconsuming, requiring multiple sequential steps. In one or more implementations described herein, a check-valve is mounted to a region of the pouch cell adjacent to the electrode stack, which can be used both to relieve internal gas pressure within the cell as well as to expose the cell to vacuum. For example, the check valve can relieve pressure within the battery cell when a threshold pressure within the battery cell is reached. Once the pressure within the battery cell drops below the threshold pressure, the valve closes automatically, due to a self-closing mechanism within the valve. After completion of the degassing process, the pouch can be heat-sealed to separate the cell from the degassing apparatus, after which the degassing apparatus can be removed.[Oi l] Once the gases are removed from the battery cell, the check valve can be removed from the battery cell, remain in place, or can be altered to serve a new function. One example of a modification that could be performed to the check valve is to convert it into a pressure-relief mechanism. Modifying the check valve to be a pressure relief mechanism can provide a safety benefit during operation of the battery cell. For example, the pressure relief mechanism can provide a controlled and directional release of hot gas and / or plasma during a thermal event, such as thermal runaway. The pressure relief mechanism can remain sealed throughout the life of the battery cell, until and unless a high threshold pressure is reached within the battery cell. To illustrate, the pressure relief mechanism may activate at a threshold pressure of 1000 kilopascals (kPa), which is a threshold pressure only likely during a high temperature excursion.

[0012] In prismatic cells, a check valve may be mounted in the same region of the external casing commonly reserved for a pressure relief system. In one or more examples, after formation, the check valve may be laser welded shut, with the weld designed to possess a specific strength, intended to break in the event of a very high pressure generated within the cell (from a thermal event, for instance). Alternatively, the check valve may be mounted adjacent to the pressure relief system and may also serve as a port for electrolyte injection into the cell. In such an embodiment, the port would first be utilized to fill electrolyte into the cell, after which a check valve would bemounted through the port. Once formation and degassing of the cell is completed, the check valve can be removed or may be left in place. Finally, a cap will be applied to the port or to the check valve and welded shut in order to prevent air ingress into the cell during its lifetime.

[0013] Figure 1 illustrates an example process 100 to remove one or more gases from a pouch cell that includes a battery stack, in accordance with one or more example implementations. The process 100 can include, at 102, providing a battery enclosure 104 including one or more battery electrodes. The battery enclosure 104 can include a casing 106. The casing 106 can comprise an outer shell of the battery enclosure 104. The casing 106 can be comprised of one or more metallic materials. For example, the casing 106 can be comprised of at least one of aluminum or one or more alloys of aluminum. In addition, the casing 106 can be comprised of stainless steel. In still other examples, the casing 106 can be comprised of at least one of nickel or one or more alloys of nickel. Further, the casing 106 can be comprised of one or more polymeric materials. To illustrate, the casing 106 can be comprised of polypropylene. In still other examples, the casing 106 can be comprised of a polyethylene terephthalate coated with aluminum or an alloy of aluminum.

[0014] At least a first electrode 108 and a second electrode 110 can be disposed in the battery enclosure 104. The first electrode 108 can include a first tab 112 that extends beyond the casing 106 and the second electrode 110 can include a second tab 114 that extends beyond the casing 106. The first tab 112 and the second tab 114 can be configured to provide connections to electrical components that are supplied power by the electrodes disposed within the battery enclosure 104. In one or more illustrative examples, the electrodes disposed in the battery enclosure 104 can have a capacity of at least about 1 ampere hour (Ah), at least about 2 Ah, at least about 5 Ah, at least about 10 Ah, at least about 25 Ah, at least about 50 Ah, at least about 75 Ah, at least about 100 Ah, or at least about 125 Ah. In one or more additional illustrative examples, the electrodes disposed in the battery enclosure 104 can have a capacity no greater than about 250 Ah, no greater than about 225 Ah, no greater than about 200 Ah, no greater than about 175 Ah, or no greater than about 150 Ah. In one or more further illustrative examples, the electrodes dispose in the battery enclosure 104 can have a capacity from about 1 Ah to about 250 Ah, from about 5 Ah to about 200 Ah, from about 25 Ah to about 150 Ah, from about 50 Ah to about 150 Ah, from about 10 Ah to about 50 Ah, from about 5 Ah to about 25 Ah, or from about 25 Ah to about 75 Ah. Although the illustrative example of Figure 1 shows a first electrode 108 and a second electrode 110 disposed in the battery enclosure 104, in other implementations, the battery enclosure 104 can include atleast 4 electrodes, at least 10 electrodes, at least 20 electrodes, at least 50 electrodes, at least 100 electrodes, at least 250 electrodes, at least 500 electrodes, at least 1000 electrodes, at least 2500 electrodes, or more.

[0015] In various examples, a stack of electrodes can be disposed in the battery enclosure 104 with the stack of electrodes comprising a plurality of electrode pairs. Individual electrode pairs can include a cathode and an anode. In one or more examples, one or more materials can be disposed between the cathode and the anode of an individual electrode pair. For example, at least one of a separator layer or an electrolyte layer can be disposed between the cathode and the anode of an individual electrode pair. In at least some examples, an electrolyte layer can be at least one of disposed between or disposed within the cathode and / or the anode.

[0016] In one or more illustrative examples, one or more cathode layers disposed in the battery enclosure 104 can include one or more cathode active materials comprised of at least one of LiNixMnyCozCh, LiNixCoyAlzO2, LiMnxNiyOz, LiMnCh, LiFePC , LiMnPCh, LiNiPC , LiCoPO-t, LiX^Os, sulfur or LiCoCh where x, y and z are stoichiometric coefficients. In at least some illustrative examples, one or more cathode layers of the battery enclosure 104 can also include one or more transition metal fluorides. In various examples, the one or more transition metal fluorides can include FeFs, Q1F2, C0F3, NiF2, MnF2, or LiFePO4, LiMmFeyPC LiNi-MmCo-Ch, LiNFCoj A Ch, LiNilCo Mn1,A O2, where w + x + y + z =1.

[0017] In at least some examples, the cathodes disposed in the battery enclosure 104 can also include one or more lithium salts. For example, the cathodes disposed in the battery enclosure 104 can include lithium succinate, lithium oxalate, lithium ketomalonate, lithium citrate, lithium oxide, lithium peroxide, lithium acetate, lithium formate, lithium hydroxide, lithium carbonate, lithium sulfate, lithium phosphate, lithium fluoride, lithium peroxide, lithium hydroxylamine, lithium oxalate, lithium succinate, lithium dimethyl succinate, lithium fumarate, lithium 2- methylfumarate, maleic acid dilithium salt, 2-m ethyl maleic acid dilithium salt, 1,4-hydroquinone dilithium salt, catechol dilithium salt, lithium poly(hydroquinone), lithium (lS,2S)-cyclopentane-1.2-dicarboxylate, lithium (lS,2S)-cyclohexane-l,2-dicarboxylate, lithium malonate, hydrazine1.2-bis(trimethyl silyl) dilithium salt, pyromellitic diimide lithium salt, naphthalenedi imide lithium salt, lithium cyanurate, or one or more combinations thereof.

[0018] In one or more additional illustrative examples, one or more anode layers disposed in the battery enclosure 104 can include one or more anode active materials comprised at least one ofgraphite, Si, Sn, Ge, Al, P, Zn, Ga, As, Cd, In, Sb, Pb, Bi, SiO, SnCh, Si, Sn, lithium metal, LiNixMnyCozCh, LiNixCoyAlzO2, LiMnxNiyOz, LiMnCh, LiFePO4, LiMnPCh, LiNiPC , LiCoPC , LiX^Os, sulfur, or LiCoCh where x, y and z are stoichiometric coefficients.

[0019] In one or more further illustrative examples, active material layers of at least one of cathode layers or anode layers disposed in the battery enclosure 104 can include at least one of one or more binding materials that include at least one of a polyvinylidene fluoride, a polyamide imide, a polyethylene oxide, a polyimide, a poly (acrylic acid), a poly (methyl methacrylate), a polyvinyl alcohol, or a polypropylene carbonate or one or more conductive additives that include at least one of carbon black particles, carbon nanotubes, or graphite particles.

[0020] In still other examples, electrodes disposed in the battery enclosure 104 can include at least one current collector layer on which the one or more active materials are disposed. In various examples, the at least one current collector layer can be comprised of one or more polymeric materials, such as polyethylene, polypropylene, polyimide, polyether ether ketone, polyester, polyamide or polyethylene naphthalate. In one or more additional examples, the current collector may comprise a polymer material, such as polyethylene, polypropylene, polyimide, polyether ether ketone, polyester, polyamide or polyethylene naphthalate, in addition to one or more metallic materials, such as copper, aluminum, titanium, nickel, or stainless steel. In one or more further examples, the at least one current collector layer can be entirely composed of one or more polymeric materials, such as polyethylene, polypropylene, polyimide, polyether ether ketone, polyester, polyamide or polyethylene naphthalate. In still other examples, the at least one current collector layer can be comprised one or more metallic materials without any polymeric materials. To illustrate, the at least one current collector layer can be comprised of at least one of copper, alloys of copper, aluminum, alloys of aluminum, titanium, alloys of titanium, nickel, alloys of nickel, or stainless steel.

[0021] Additionally, an encapsulating thin fdm can be deposited on one or more electrode active material layers. In one or more examples, the encapsulating thin fdm can include at least one of one or more organic materials or one or more inorganic materials. In one or more illustrative examples, the encapsulating thin fdm can include a polyamide, a polyimide, polyethylene glycol, one or more metal oxides, one or more metal phosphates, one or more metal sulphates, one or more metalcones, or one or more combinations thereof. In various examples, the encapsulating thin fdm can reduce or prevent electrochemical side reactions from taking place between active materialsand an electrolyte present in a battery. In at least some examples, the encapsulating thin film can be formed using one or more solution-phase techniques.

[0022] The battery enclosure 104 can include a first section 116 and a second section 118. The first section 116 can be adjacent to the second section 118. In at least some examples, the first section 116 and the second section 118 can be divided by a boundary 120. In one or more examples, the boundary 120 can be a physical boundary. In one or more additional examples, the boundary 120 can include a porous material. In one or more further examples, the boundary 120 can include one or more polymeric materials. In various examples, the stack of battery electrodes can be disposed in the first section 116.

[0023] The second section 118 can include a port 122. In at least some examples, gas inside the battery enclosure 104 can be discharged through the port 122. In one or more illustrative examples, the port 122 can include a valve. In various examples, the port 122 can include a valve that is located within an opening or a recessed portion of the casing 106. In this way, the port 122 can be incorporated into the casing 106. In one or more illustrative examples, the port 122 can include a valve that is closed in response to the pressure within the battery enclosure 104 being less than a threshold pressure. In one or more additional illustrative examples, the port 122 can include a valve that comprises at least one of a spring-loaded ball, a gasket, a plunger, a check valve, or a diaphragm valve. In one or more implementations where the port 122 includes a check valve, the check valve can comprise a ball check valve, a swing check valve, a wafer check valve, a tilting disc check valve, a single leaf check valve, a double leaf check valve, a multi -half check valve, a nozzle check valve, a butterfly check valve, a lift check valve, or a one-way check valve. In various examples, the port 122 can include a valve that discharges gas within the battery enclosure 104 in response to a pressure within the battery enclosure 104 being at least about 3 kilopascals (kPa), at least about 5 kPa, at least about 8 kPa, at least about 10 kPa, at least about 12 kPa, at least about 15 kPa, at least about 18 kPa, at least about 20 kPa, at least about 22 kPa, at least about 25 kPa, at least about 28 kPa, or at least about 30 kPa. In still other examples, the port 122 can include a valve that discharges gas within the battery enclosure 104 in response to pressures within the battery enclosure 104 from about 3 kPa to about 50 kPa, 3 kPa to about 40 kPa, from about 3 kPa to about 30 kPa, from about 3 kPa to about 20 kPa, from about 5 kPa to about 50 kPa, from about 5 kPa to about 40 kPa, from about 5 kPa to about 30 kPa, from about 5 kPa to about 20 kPa, fromabout 10 kPa to about 50 kPa, from about 10 kPa to about 40 kPa, from about 10 kPa to about 30 kPa, from about 20 kPa to about 50 kPa, or from about 20 kPa to about 40 kPa.

[0024] At 124, the process 100 can include performing an initial electrode charging process. In one or more examples, the initial electrode charging process can be referred to herein as a formation process. In at least some examples, the formation process can be performed after an amount of electrolyte is distributed within the battery enclosure 104. In various examples, the amount of electrolyte can be introduced into the battery enclosure 104 via the port 122. In one or more illustrative examples, the addition of the electrolyte into the battery enclosure 104 can be referred to herein as a wetting process. During the wetting process, the electrolyte can contact the electrode layers disposed in the second section 118 of the battery enclosure 104. In one or more scenarios, the electrolyte can diffuse into pores of the electrode layers during the wetting process. In one or more additional illustrative examples, the wetting process can have a duration of several hours to several days or longer. In one or more further illustrative examples, the wetting process can be performed at temperatures of at least about 40 °C, at least about 50 °C, at least about 60 °C, at least about 70 °C, at least about 80 °C, at least about 90 °C, or at least about 100 °C.

[0025] In various examples, electrolytes added to the battery enclosure 104 can be comprised of one or more lithium containing salts. For example, electrolytes added to the battery enclosure 104 via the port 122 can include at least one of LiPFe, LiBF4, or LiClO4, in an organic solvent. In one or more example, the organic solvent can comprise one or more of the following: ethylene carbonate, ethyl methyl carbonate, propylene carbonate, glyme, diglyme, dioxolane, vinylene carbonate, propane sultone, diethyl carbonate, dimethyl carbonate, sulfolane. Additionally, the organic solvent can comprise an ionic liquid such as a salt containing a quaternary phosphorous or nitrogen cation such as 1 -ethyl -3 -methyl imidazolium or 1 -butyl- 1 -methyl pyrrolidinium. In one or more further examples, the lithium-containing salt can comprise one or more of the following: lithium hexafluorophosphate, lithium perchlorate, lithium difluoro(oxalate)borate, lithium trifluoromethanesulfonate, lithium tetrafluoroborate, lithium bis(trifluoromethanesulfonimide), lithium bis(fluorosulfonyl)imide.

[0026] After wetting of the electrodes with the electrolyte, the formation process can include charging the electrodes at relatively low currents and relatively low voltages. Charge and discharge cycles performed during the formation process can have durations from several hours to one or more days. To illustrate, a charge / discharge cycle during the formation process can have a durationfrom about 2 hours to about 24 hours or from about 4 hours to about 18 hours. In one or more examples, the formation process can be performed at charge / discharge rates of about 0.1C - 0.2C or about 0.2C - 0.5C, where C is the cell capacity. Voltages applied during the formation process can be from about 0.1 volts (V) to about 5 V, from about 0.2 V to about 2.5 V, or from about 0.1 V to 1.5 V. The conditions for the formation process can be based on the materials of the electrodes and electrolyte included in the battery enclosure 104 in addition to sizes of the electrodes. In at least some examples, a solid electrolyte interface layer can be formed during the formation process. The solid electrolyte interface layer can comprise a passivation layer that is electrically resistive but enables Li+ ions to pass through. The solid electrolyte interface layer can minimize lithium loss, electrolyte depletion, and capacity decrease during the operation lifetime of the electrodes included in the battery enclosure 104.

[0027] During the initial electrode charging process performed at 124, gas can build up within the battery enclosure 104. In at least some examples, the gases produced during the formation process can include at least one of CO2, CO, C2H4, C2H6, or H2. To prevent damage to components located in the battery enclosure 104, the process 100 can include, at 126, causing one or more gases to be released from the battery enclosure 104. In one or more examples, at least a portion of the gases can be released in response to a valve included in the port 122 being activated. For example, gases produced during the formation process can be released via the port in response to the pressure within the battery enclosure 104 being at least a threshold pressure at which a valve included in the port 122 is activated. In one or more additional examples, one or more degassing operations can be performed to remove gases from the battery enclosure 104. To illustrate, negative pressure, such as a vacuum, can be applied to the battery enclosure 104 via the port 122.

[0028] After the one or more gases are released from the battery enclosure 104, the process 100 can move to 128 where the battery enclosure 104 is modified to produce a battery package. In one or more first illustrative examples, a first battery package 130 can be produced in response to modifications made to the battery enclosure 104 after one or more degassing operations. In at least some examples, the first battery package 130 can include a top surface, a bottom surface, and four side surfaces. For example, the second section 118 of the battery enclosure 104 can be removed from or separated from the first section 116. In one or more illustrative examples, the second section 118 of the battery enclosure 104 can be at least one of removed from or separated from the first section 116 by a laser cutting process. In one or more additional illustrative examples, thesecond section 1 18 of the battery enclosure 104 can be removed from or separated from the first section 116 by mechanically cutting the battery enclosure 104 at or near the boundary 120 and then sealing any opening made due to the cutting process. In at least some examples, the seal can be formed using one or more heat sealing processes. In various examples, the seal can be formed along at least about 30%, at least about 40%, at least about 50%, at least about 60%, at least about 70%, at least about 80%, or least about 90%, at least about 95%, or at least about 99% of the side surface of the battery enclosure 104 where the cut was made to remove the second section 118.

[0029] In one or more second illustrative examples, a second battery package 132 can be produced in response to modifications made to the battery enclosure 104 at operation 128. In various examples, the second battery package 132 can include the second section 118 with modifications to the port 122 to produce a modified casing section 134. For example, a valve included in the port 122 can be removed and an opening in the casing 106 can be sealed using one or more materials. In at least some examples, the opening in the casing 106 produced by removal of the port 122 can be filled by one or more metallic materials. In one or more examples, the modified casing section 134 can include one or more metallic materials that are the same as or similar to one or more metallic materials used to form the casing 106. In one or more additional examples, the modified casing section 134 can include one or more metallic materials that are different from one or more metallic materials of the casing 106. In still other examples, a valve included in the port 122 can be replaced by a different type of valve to form the modified casing section 134.

[0030] In various examples, an initial volume of the battery enclosure 104 prior to the initial charging process performed at 124 can be at least about 100 cm3, at least about 150 cm3, at least about 200 cm3, at least about 250 cm3, at least about 300 cm3, at least about 350 cm3, or at least about 400 cm3. In one or more additional examples, an initial volume of the battery enclosure 104 can be no greater than about 2000 cm3, no greater than about 1800 cm3, no greater than about 1500 cm3, no greater than about 1200 cm3, no greater than about 1000 cm3, no greater than about 900 cm3, no greater than about 800 cm3, no greater than about 700 cm3, no greater than about 600 cm3, or no greater than about 500 cm3. In one or more illustrative examples, the initial volume of the battery enclosure 104 can be from about 100 cm3to about 2000 cm3, from about 200 cm3to about 1800 cm3, from about 300 cm3to about 1500 cm3, from about 100 cm3to about 1000 cm3, from about 1000 cm3to about 2000 cm3, from about 800 cm3to about 1800 cm3, from about 200 cm3toabout 800 cm3, from about 300 cm3to about 500 cm3, from about 100 cm3to about 400 cm3, from about 200 cm3to about 400 cm3, or from about 100 cm3to about 500 cm3.

[0031] Further, an additional volume of at least one of the first battery package 130 or the second battery package 132 can be no greater than about 80% of the initial volume of the battery enclosure 104, no greater than about 70% of the initial volume of the battery enclosure 104, no greater than about 60% of the initial volume of the battery enclosure 104, or no greater than about 50% of the initial volume of the battery enclosure 104. In various additional illustrative examples, an additional volume of at least one of the first battery package 130 or the second battery package 132 can be from about 100 cm3to about 1600 cm3, from about 200 cm3to about 1400 cm3, from about 500 cm3to about 1200 cm3, from about 600 cm3to about 1500 cm3, from about 50 cm3to about 800 cm3, from about 100 cm3to about 500 cm3, from about 50 cm3to about 300 cm3, from about 200 cm3to about 600 cm3, or from about 100 cm3to about 400 cm3.

[0032] Figure 2 illustrates an example process 200 to remove one or more gases from a prismatic cell that includes at least one battery stack, in accordance with one or more example implementations. The process 200 can include, at 202, inserting a battery stack 204 into a battery enclosure 206. The battery stack 204 can include one or more battery electrodes. In one or more examples, the battery stack 204 can be inserted into the battery enclosure 206 via an opening 208. The battery enclosure 206 can include a casing that comprises an outer shell of the battery enclosure 206. In at least some examples, the battery enclosure 206 can be comprised of one or more metallic materials. For example, the battery enclosure 206 can be comprised of at least one of aluminum or one or more alloys of aluminum. In addition, the battery enclosure 206 can be comprised of stainless steel. In still other examples, the battery enclosure 206 can be comprised of at least one of nickel or one or more alloys of nickel.

[0033] The battery stack 204 can have a capacity of at least about 1 ampere hour (Ah), at least about 2 Ah, at least about 5 Ah, at least about 10 Ah, at least about 25 Ah, at least about 50 Ah, at least about 75 Ah, at least about 100 Ah, or at least about 125 Ah. In one or more additional illustrative examples, the battery stack 204 can have a capacity no greater than about 250 Ah, no greater than about 225 Ah, no greater than about 200 Ah, no greater than about 175 Ah, or no greater than about 150 Ah. In one or more further illustrative examples, the battery stack 204 can have a capacity from about 1 Ah to about 250 Ah, from about 5 Ah to about 200 Ah, from about25 Ah to about 150 Ah, from about 50 Ah to about 150 Ah, from about 10 Ah to about 50 Ah, from about 5 Ah to about 25 Ah, or from about 25 Ah to about 75 Ah.

[0034] In various examples, the battery stack 204 can include a stack of electrodes that is disposed in the battery enclosure 206 with the stack of electrodes comprising a plurality of electrode pairs. Individual electrode pairs can include a cathode and an anode. In one or more examples, one or more materials can be disposed between the cathode and the anode of an individual electrode pair. For example, at least one of a separator layer or an electrolyte layer can be disposed between the cathode and the anode of an individual electrode pair. In at least some examples, an electrolyte layer can be at least one of disposed between or disposed within the cathode and / or the anode.

[0035] In one or more illustrative examples, one or more cathode layers of the battery stack 204 can include one or more cathode active materials comprised of at least one of LiNixMnyCozO2, LiNixCoyAlzCh, LiMnxNiyOz, LiMnCh, LiFePO4, LiMnPC , LiNiPC , LiCoPO4, LiV2Os, sulfur or LiCoCh where x, y and z are stoichiometric coefficients. In at least some illustrative examples, one or more cathode layers of the battery stack 204 can also include one or more transition metal fluorides. In various examples, the one or more transition metal fluorides can include FeFa, CuF2, CoFs, NiF2, MnF2, or LiFePO4, LiMn FerPO4. LiNi.vMnvCo-O2, LiNi CovA-O2, LiNiwCoxMnyAzO2, where w + x +y + z =l.

[0036] In at least some examples, the cathodes disposed in the battery stack 204 can also include one or more lithium salts. For example, the cathodes disposed in the battery stack 204 can include lithium succinate, lithium oxalate, lithium ketomalonate, lithium citrate, lithium oxide, lithium peroxide, lithium acetate, lithium formate, lithium hydroxide, lithium carbonate, lithium sulfate, lithium phosphate, lithium fluoride, lithium peroxide, lithium hydroxylamine, lithium oxalate, lithium succinate, lithium dimethyl succinate, lithium fumarate, lithium 2-methylfumarate, maleic acid dilithium salt, 2-methyl maleic acid dilithium salt, 1 ,4-hydroquinone dilithium salt, catechol dilithium salt, lithium poly(hydroquinone), lithium (lS,2S)-cyclopentane-l,2-dicarboxylate, lithium (lS,2S)-cyclohexane-l,2-dicarboxylate, lithium malonate, hydrazine 1,2- bis(trimethylsilyl) dilithium salt, pyromellitic diimide lithium salt, naphthalenediimide lithium salt, lithium cyanurate, or one or more combinations thereof.

[0037] In one or more additional illustrative examples, one or more anode layers disposed in the battery stack 204 can include one or more anode active materials comprised at least one of graphite, Si, Sn, Ge, Al, P, Zn, Ga, As, Cd, In, Sb, Pb, Bi, SiO, SnCh, Si, Sn, lithium metal, LiNixMnyCozO2,iNixCoyAlzCh, LiMnxNiyOz, LiMnCh, LiFePCh, LiMnPC , LiNiPO4, LiCoPO4, UV2O5, sulfur, or LiCoCh where x, y and z are stoichiometric coefficients.

[0038] In one or more further illustrative examples, active material layers of at least one of cathode layers or anode layers disposed in the battery stack 204 can include at least one of one or more binding materials that include at least one of a polyvinylidene fluoride, a polyamide imide, a polyethylene oxide, a polyimide, a poly (acrylic acid), a poly (methyl methacrylate), a polyvinyl alcohol, or a polypropylene carbonate or one or more conductive additives that include at least one of carbon black particles, carbon nanotubes, or graphite particles.

[0039] In still other examples, electrodes disposed in the battery stack 204 can include at least one current collector layer on which the one or more active materials are disposed. In various examples, the at least one current collector layer can be comprised of one or more polymeric materials, such as polyethylene, polypropylene, polyimide, polyether ether ketone, polyester, polyamide or polyethylene naphthalate. In one or more additional examples, the current collector may comprise a polymer material, such as polyethylene, polypropylene, polyimide, polyether ether ketone, polyester, polyamide or polyethylene naphthalate, in addition to one or more metallic materials, such as copper, aluminum, titanium, nickel, or stainless steel. In one or more further examples, the at least one current collector layer can be entirely composed of one or more polymeric materials, such as polyethylene, polypropylene, polyimide, polyether ether ketone, polyester, polyamide or polyethylene naphthalate. In still other examples, the at least one current collector layer can be comprised one or more metallic materials without any polymeric materials. To illustrate, the at least one current collector layer can be comprised of at least one of copper, alloys of copper, aluminum, alloys of aluminum, titanium, alloys of titanium, nickel, alloys of nickel, or stainless steel.

[0040] Additionally, an encapsulating thin film can be deposited on one or more electrode active material layers. In one or more examples, the encapsulating thin film can include at least one of one or more organic materials or one or more inorganic materials. In one or more illustrative examples, the encapsulating thin film can include a polyamide, a polyimide, polyethylene glycol, one or more metal oxides, one or more metal phosphates, one or more metal sulphates, one or more metalcones, or one or more combinations thereof. In various examples, the encapsulating thin film can reduce or prevent electrochemical side reactions from taking place between active materialsand an electrolyte present in a battery. In at least some examples, the encapsulating thin film can be formed using one or more solution-phase techniques.

[0041] At 210, the process 200 can include placing a top 212 onto the battery enclosure 206. In one or more examples, the top 212 can be placed on the battery enclosure 206 by securing the top 212 to the battery enclosure 206. In various examples, the top 212 can be comprised of one or more metallic materials. In at least some examples, the top 212 can be comprised of the same or similar metallic materials as the battery enclosure 206. In one or more illustrative examples, the top 212 can be secured to the battery enclosure 206 by laser welding.

[0042] The top 212 can include a vent port 214. The top 212 can also include a fill port 216. The vent port 214 can be configured to enable a negative pressure device to be coupled to the top 212 that is coupled to the battery enclosure 206. In one or more examples, gases produced during operation of the battery stack 204 can be removed from the battery enclosure 206 via the vent port 214 when a negative pressure device is coupled to the vent port 214 and operated to withdraw one or more gases from the battery enclosure 206. In one or more illustrative examples, a valve can be located at a same position on the top 212 as the vent port 214. The valve can also be configured to enable one or more gases to be discharged from the battery enclosure 206 in response to a threshold pressure being present within the battery enclosure 206. Additionally, the fill port 216 can be used to add electrolyte to the battery enclosure 206. For example, one or more electrolyte materials can be added to the battery enclosure 206 via the fill port 216. In one or more additional illustrative examples, the valve can be located at a same position on the top 212 of the battery enclosure 206 as the fill port 216. In these scenarios, the valve can operate to enable substances to pass into the battery enclosure 206 in response to external pressure being applied at the location of the fill port 216 and the valve can operate to enable one or more gases within the battery enclosure 206 to be discharged in response to a threshold pressure being present within the battery enclosure 206. In still other illustrative examples, the top 212 coupled to the battery enclosure 206 can include a valve port 218 that is located at different and separate positions than a location of the vent port 214 and a location of the fill port 216. In these instances, the valve port 218 can include a valve that is configured to discharge one or more gases from the battery enclosure 206 in response to a threshold pressure being present in the battery enclosure 206.

[0043] In various examples one or more valves that are located at the vent port 214, at the fill port 216, and / or at the valve port 218 can be disposed within an opening or a recessed portion of thetop 202. In this way, the valve can be incorporated into the top 202. In one or more illustrative examples, the one or more valves can be closed in response to the pressure within the battery enclosure 206 being less than a threshold pressure. In one or more additional illustrative examples, the one or more valves can comprise at least one of a spring-loaded ball, a gasket, a plunger, a check valve, or a diaphragm valve. In one or more implementations where the one or more valves include a check valve, the check valve can comprise a ball check valve, a swing check valve, a wafer check valve, a tilting disc check valve, a single leaf check valve, a double leaf check valve, a multi -half check valve, a nozzle check valve, a butterfly check valve, a lift check valve, or a oneway check valve. In at least some examples, the one or more valves can be located in the top 212 at the vent port 214, the fill port 216, the valve port 218, or one or more combinations thereof, and can discharge one or more gases within the battery enclosure 206 in response to a pressure within the battery enclosure 206 being at least about 3 kilopascals (kPa), at least about 5 kPa, at least about 8 kPa, at least about 10 kPa, at least about 12 kPa, at least about 15 kPa, at least about 18 kPa, at least about 20 kPa, at least about 22 kPa, at least about 25 kPa, at least about 28 kPa, or at least about 30 kPa. In still other examples, the one or more valves can be located in the top 212 at the vent port 214, the fill port 216, the valve port 218, or one or more combinations thereof, and can discharge one or more gases within the battery enclosure 206 in response to pressures within the battery enclosure 206 from about 3 kPa to about 50 kPa, 3 kPa to about 40 kPa, from about 3 kPa to about 30 kPa, from about 3 kPa to about 20 kPa, from about 5 kPa to about 50 kPa, from about 5 kPa to about 40 kPa, from about 5 kPa to about 30 kPa, from about 5 kPa to about 20 kPa, from about 10 kPa to about 50 kPa, from about 10 kPa to about 40 kPa, from about 10 kPa to about 30 kPa, from about 20 kPa to about 50 kPa, or from about 20 kPa to about 40 kPa.

[0044] At 220, the process 200 can include performing an initial electrode charging process. In one or more examples, the initial electrode charging process can be referred to herein as a formation process. In at least some examples, the formation process can be performed after an amount of electrolyte is distributed within the battery enclosure 206. In various examples, the amount of electrolyte can be introduced into the battery enclosure 206 via the fill port 216. In one or more illustrative examples, the addition of the electrolyte into the battery enclosure 206 can be referred to herein as a wetting process. During the wetting process, the electrolyte can contact the electrode layers of the battery stack 204 disposed in the battery enclosure 206. In one or more scenarios, the electrolyte can diffuse into pores of the electrode layers during the wetting process.In one or more additional illustrative examples, the wetting process can have a duration of several hours to several days or longer. In one or more further illustrative examples, the wetting process can be performed at temperatures of at least about 40 °C, at least about 50 °C, at least about 60 °C, at least about 70 °C, at least about 80 °C, at least about 90 °C, or at least about 100 °C.

[0045] In various examples, electrolytes added to the battery enclosure 206 can be comprised of one or more lithium containing salts. For example, electrolytes added to the battery enclosure 206 via the fill port 216 can include at least one of LiPFe, LiBF4, or LiCICU, in an organic solvent. In one or more example, the organic solvent can comprise one or more of the following: ethylene carbonate, ethyl methyl carbonate, propylene carbonate, glyme, diglyme, dioxolane, vinylene carbonate, propane sultone, diethyl carbonate, dimethyl carbonate, sulfolane. Additionally, the organic solvent can comprise an ionic liquid such as a salt containing a quaternary phosphorous or nitrogen cation such as 1 -ethyl -3 -methyl imidazolium or 1 -butyl- 1 -methyl pyrrolidinium. In one or more further examples, the lithium-containing salt can comprise one or more of the following: lithium hexafluorophosphate, lithium perchlorate, lithium difluoro(oxalate)borate, lithium trifluoromethanesulfonate, lithium tetrafluoroborate, lithium bis(trifluoromethanesulfonimide), lithium bis(fluorosulfonyl)imide.

[0046] After wetting of the electrodes with the electrolyte, the formation process can include charging the electrodes at relatively low currents and relatively low voltages. Charge and discharge cycles performed during the formation process can have durations from several hours to one or more days. To illustrate, a charge / discharge cycle during the formation process can have a duration from about 2 hours to about 24 hours or from about 4 hours to about 18 hours. In one or more examples, the formation process can be performed at charge / discharge rates of about 0.1C - 0.2C or about 0.2C - 0.5C, where C is the cell capacity. Voltages applied during the formation process can be from about 0.1 volts (V) to about 5 V, from about 0.2 V to about 2.5 V, or from about 0.1 V to 1.5 V. The conditions for the formation process can be based on the materials of the electrodes and electrolyte included in the battery enclosure 206 in addition to sizes of the electrodes. In at least some examples, a solid electrolyte interface layer can be formed during the formation process. The solid electrolyte interface layer can comprise a passivation layer that is electrically resistive but enables Li+ ions to pass through. The solid electrolyte interface layer can minimize lithium loss, electrolyte depletion, and capacity decrease during the operation lifetime of the electrodes included in the battery enclosure 206.

[0047] During the initial electrode charging process performed at 220, gas can build up within the battery enclosure 206. In at least some examples, the gases produced during the formation process can include at least one of CO2, CO, C2H4, C2H6, or H2. To prevent damage to components located in the battery enclosure 206, the process 200 can include, at 222, causing one or more gases to be released from the battery enclosure 206. In one or more examples, at least a portion of the gases can be released in response to a valve located in the top 212 being activated. For example, gases produced during the formation process can be released via at least one of a valve located in the vent port 214, a valve located in the fill port 216, and / or a valve located in the valve port 218 in response to the pressure within the battery enclosure 206 being at least a threshold pressure at which the valve is activated. In one or more additional examples, one or more degassing operations can be performed to remove gases from the battery enclosure 206. To illustrate, negative pressure, such as a vacuum, can be applied to the battery enclosure 206 via the vent port 214.

[0048] After the one or more gases are released from the battery enclosure 206, the process 200 can move to 224 where the battery enclosure is modified to produce a battery package 226. In one or more examples, the battery package 226 can be produced by placing a cover 228 on the top 212 and securing the cover 228 to at least one of the top 212 or the battery enclosure 206. In various examples, the cover 228 can be secured to at least one of the top 212 or the battery enclosure 206 by applying one or more adhesives to the cover 228. In one or more additional examples, , the cover 228 can be secured to at least one of the top 212 or the battery enclosure 206 by a laser welding process. In at least some examples, the cover 228 can be comprised of one or more metallic materials.

[0049] In one or more examples, the one or more valves located in the top 212 of the battery enclosure 206 can be modified to produce the battery package 226. For example, one or more valves located in the top 212 at the vent port 214, at the fill port 216, at the valve port 218, or at one or more combinations thereof, can be replaced by a rupture disc. In various examples, the rupture disc can be configured to break at pressures within the battery enclosure 206 that are greater than the threshold pressure at which the one or more valves operate. In at least some examples, the rupture disc can be configured to break at pressures within the battery enclosure 206 that are produced during a thermal runaway event. In one or more illustrative examples, the rupture disc can be configured to break at pressures from about 500 kPa to about 5000 kPa, from about 1000kPa to about 4000 kPa, from about 2000 kPa to about 5000 kPa, or from about 500 kPa to about 2000 kPa.

[0050] In various examples, a volume of the battery package 226 can be at least about 100 cm3, at least about 150 cm3, at least about 200 cm3, at least about 250 cm3, at least about 300 cm3, at least about 350 cm3, or at least about 400 cm3. In one or more additional examples, a volume of the battery package 226 can be no greater than about 2000 cm3, no greater than about 1800 cm3, no greater than about 1500 cm3, no greater than about 1200 cm3, no greater than about 1000 cm3, no greater than about 900 cm3, no greater than about 800 cm3, no greater than about 700 cm3, no greater than about 600 cm3, or no greater than about 500 cm3. In one or more illustrative examples, the volume of the battery package 226 can be from about 100 cm3to about 2000 cm3, from about 200 cm3to about 1800 cm3, from about 500 cm3to about 1500 cm3, from about 800 cm3to about 1800 cm3, from about 200 cm3to about 1200 cm3, from about 300 cm3to about 500 cm3, from about 100 cm3to about 400 cm3, from about 200 cm3to about 400 cm3, or from about 100 cm3to about 500 cm3.

[0051] Figure 3 includes a flow diagram of an example method 300 to remove one or more gases from a battery cell that includes a battery stack, in accordance with one or more example implementations. At 302, the method 300 can include providing a battery enclosure that includes a casing. The battery enclosure can include a first section and a second section. Additionally, a plurality of lithium-ion battery electrodes can be located in the first section and a port can be located on a portion of the casing that corresponds to the second section. In one or more examples, the first section can be adj acent to the second section. In at least some examples, the second section can comprise a top that is secured to the battery enclosure.

[0052] In various examples, the battery enclosure can be comprised of one or more metallic materials. For example, the battery enclosure can be comprised of at least one of aluminum, alloys of aluminum, nickel, alloys of nickel, or stainless steel. Additionally, the battery enclosure can be comprised of one or more polymeric materials. In one or more illustrative examples, the lithium- ion battery package can be a pouch cell. In one or more additional illustrative examples, the lithium-ion battery package can be a prismatic cell.

[0053] The port included in the battery enclosure can have one or more functions. In one or more examples, an amount of electrolyte can be injected into the battery enclosure through the port. In addition, before modifying the battery enclosure, the port can include a valve that closes inresponse to the pressure within the battery enclosure being less than the threshold pressure. In one or more illustrative examples, the port can include a valve that comprises at least one of a spring- loaded ball, a gasket, a plunger, a check valve, or a diaphragm valve. In one or more additional examples where the port includes a check valve, the check valve can comprise a ball check valve, a swing check valve, a wafer check valve, a tilting disc check valve, a single leaf check valve, a double leaf check valve, a multi-half check valve, a nozzle check valve, a butterfly check valve, a lift check valve, or a one-way check valve

[0054] Additionally, at 304, the method 300 can include performing an initial charging process for the plurality of lithium-ion battery electrodes. The initial charging process can cause formation of one or more gases within the battery enclosure. In various examples, an interface can be disposed between the first section and the second section that enables the one or more gases generated in the first section to move into the second section. In one or more illustrative examples, the interface can include a porous membrane comprised of one or more polymeric materials.

[0055] Further, the method 300 can include, at 306, causing the one or more gases to be released out of the battery enclosure through the port in response to a pressure within the battery enclosure being at least a threshold pressure. The threshold pressure can be from about 3 kilopascals (kPa) to about 6 kPa. In at least some examples, after performing the initial charging process, negative pressure can be applied to the battery enclosure to remove additional amounts of the one or more gases from the battery enclosure.

[0056] The method 300 can also include, at 308, modifying the battery enclosure to produce a lithium-ion battery package. In one or more examples, the modification of the battery enclosure can be performed after completion of the initial charging process and after the pressure within the battery enclosure is less than the threshold pressure. In at least some examples, modifying the battery enclosure can include removing the second section of the battery enclosure. In one or more illustrative examples, modifying the battery enclosure can include removing the second section of the battery enclosure through a mechanical cutting process following by a heat sealing process. In one or more additional illustrative examples, modifying the battery enclosure can include removing the second section of the battery enclosure through a laser cutting process.

[0057] In various examples, the port can include a valve and the battery enclosure can be modified by replacing the valve with a rupture disc. The rupture disc can be configured to break at an additional threshold pressure that is from about 2000 kPa to about 5000 kPa. In still otherexamples, the port can include a valve and modifying the battery enclosure can include removing the valve to form an opening and sealing the opening. In one or more further examples, modifying the battery enclosure can include forming a seal between the first section and a second section.

[0058] In one or more examples, the battery enclosure can have a first internal volume and the lithium-ion battery package can have a second internal volume that is different from the first internal volume. For example, after modifying the battery enclosure to produce the lithium-ion battery package, the volume of the lithium-ion battery package can be reduced with respect to an initial volume of the enclosure before being modified. In one or more illustrative examples, the second internal volume of the lithium-ion battery package can be at least 0.7 times less than the first internal volume of the battery enclosure, at least 0.6 times less than the first internal volume of the battery enclosure, at least 0.5 times less than the first internal volume of the battery enclosure, at least 0.4 times less than the first internal volume of the battery enclosure, at least 0.3 times less than the first internal volume of the battery enclosure, at least 0.2 times less than the first internal volume of the battery enclosure, or at least 0.1 times less than the first internal volume of the battery enclosure. In various examples, the first internal volume of the lithium-ion battery package can be from about 500 cm3to about 2000 cm3. Further, the second internal volume of the lithium-ion battery package can be from about 200 cm3to about 1500 cm3.

[0059] In view of the above-described implementations of subject matter this application discloses the following list of examples, wherein one feature of an example in isolation or more than one feature of an example, taken in combination and, optionally, in combination with one or more features of one or more further examples are further examples also falling within the disclosure of this application.

[0060] Example 1 is a method comprising: providing a battery enclosure that includes, a casing, the battery enclosure including a first section and a second section, wherein a plurality of lithium- ion battery electrodes are located in the first section and a port is located on a portion of the casing that corresponds to the second section; performing an initial charging process for the plurality of lithium-ion battery electrodes, wherein the initial charging process causes formation of one or more gases within the battery enclosure; causing the one or more gases to be released out of the battery enclosure through the port in response to a pressure within the battery enclosure being at least a threshold pressure; and after completion of the initial charging process and after the pressurewithin the battery enclosure is less than the threshold pressure, modifying the battery enclosure to produce a lithium-ion battery package.

[0061] In Example 2, the subject matter of Example 1 includes, wherein modifying the battery enclosure includes removing the second section of the battery enclosure.

[0062] In Example 3, the subject matter of Example 2 includes, wherein the second section of the battery enclosure is removed through a mechanical cutting process following by a heat sealing process.

[0063] In Example 4, the subject matter of Examples 2-3 includes, wherein the second section of the battery enclosure is removed through a laser cutting process.

[0064] In Example 5, the subject matter of Examples 1-4 includes, wherein the port includes a valve and modifying the battery enclosure includes replacing the valve with a rupture disc.

[0065] In Example 6, the subject matter of Example 5 includes, wherein the rupture disc is configured to break at an additional threshold pressure.

[0066] In Example 7, the subject matter of Example 6 includes, wherein the additional threshold pressure is from about 2000 kPa to about 5000 kPa.

[0067] In Example 8, the subject matter of Examples 1-7 includes, wherein the port includes a valve and modifying the battery enclosure includes: removing the valve to form an opening; and sealing the opening.

[0068] In Example 9, the subject matter of Examples 1-8 includes, wherein the threshold pressure is from about 3 kilopascals (kPa) to about 6 kPa.

[0069] In Example 10, the subject matter of Examples 1-9 includes, wherein the first section is adjacent to the second section.

[0070] In Example 11, the subject matter of Examples 1-10 includes, wherein modifying the battery enclosure includes forming a seal between the first section and a second section.

[0071] In Example 12, the subject matter of Examples 1—11 includes, wherein an interface is disposed between the first section and the second section that enables the one or more gases generated in the first section to move into the second section.

[0072] In Example 13, the subject matter of Example 12 includes, wherein the interface includes a porous membrane comprised of one or more polymeric materials.

[0073] In Example 14, the subject matter of Examples 1-13 includes, after performing the initial charging process, applying negative pressure to the battery enclosure to remove additional amounts of the one or more gases from the battery enclosure.

[0074] In Example 15, the subject matter of Examples 1-14 includes, injecting an amount of electrolyte into the battery enclosure through the port.

[0075] In Example 16, the subject matter of Examples 1-15 includes, wherein, before modifying the battery enclosure, the port includes a valve that closes in response to the pressure within the battery enclosure being less than the threshold pressure.

[0076] In Example 17, the subject matter of Examples 1-16 includes, wherein the port includes a valve that comprises at least one of a spring-loaded ball, a gasket, a plunger, a check valve, or a diaphragm valve.

[0077] In Example 18, the subject matter of Example 17 includes, wherein the port includes the check valve and the check valve comprises a ball check valve, a swing check valve, a wafer check valve, a tilting disc check valve, a single leaf check valve, a double leaf check valve, a multi-half check valve, a nozzle check valve, a butterfly check valve, a lift check valve, or a one-way check valve.

[0078] In Example 19, the subject matter of Examples 1-18 includes, wherein the battery enclosure is comprised of one or more metallic materials.

[0079] In Example 20, the subject matter of Example 19 includes, wherein the one or more metallic materials include at least one of aluminum, alloys of aluminum, nickel, alloys of nickel, or stainless steel.

[0080] In Example 21, the subject matter of Examples 1-20 includes, wherein the battery enclosure is comprised of one or more polymeric materials.

[0081] In Example 22, the subject matter of Examples 1-21 includes, wherein the lithium-ion battery package is a pouch cell.

[0082] In Example 23, the subject matter of Examples 1-22 includes, wherein the lithium-ion battery package is a prismatic cell.

[0083] In Example 24, the subject matter of Example 23 includes, wherein the second section is a top that is secured to the battery enclosure.

[0084] In Example 25, the subject matter of Examples 1-24 includes, wherein the battery enclosure has a first internal volume and the lithium-ion battery package has a second internal volume that is different from the first internal volume.

[0085] In Example 26, the subject matter of Example 25 includes, wherein the second internal volume of the lithium-ion battery package is at least 0.5 times less than the first internal volume of the battery enclosure.

[0086] In Example 27, the subject matter of Examples 25-26 includes, wherein the second internal volume of the lithium-ion battery package is from about 200 cm3to about 1500 cm3.

[0087] In Example 28, the subject matter of Examples 25-27 includes, wherein the first internal volume of the lithium-ion battery package is from about 500 cm3to about 2000 cm3.

[0088] Example 29 is an apparatus comprising: a pouch cell battery package including: a casing forming an outer shell of the pouch cell battery package, wherein a port is disposed within the casing, the port being configured to release gas within the casing in response to a pressure within the casing being at least a threshold pressure; and a plurality of battery electrodes disposed within the pouch cell battery package.

[0089] In Example 30, the subject matter of Example 29 includes, wherein: the pouch cell battery package includes a first section and a second section adjacent to the first section; the plurality of battery electrodes are disposed in the first section; and the port is disposed in relation to the second section.

[0090] In Example 31, the subject matter of Example 30 includes, wherein a boundary is disposed between the first section and the second section, the boundary including a porous polymeric material.

[0091] In Example 32, the subject matter of Examples 29-31 includes, wherein: the pouch cell battery package comprises a top surface, a bottom surface, and four side surfaces; and a seal is formed along a side surface of the four side surfaces.

[0092] In Example 33, the subject matter of Example 32 includes, wherein the seal is formed along at least about 50% of the side surface.

[0093] In Example 34, the subject matter of Examples 29-33 includes, wherein the threshold pressure is from about 3 kPa to about 30 kPa.

[0094] In Example 35, the subject matter of Examples 29-34 includes, wherein the port is a seal of an opening in the casing and the seal is comprised of one or more metallic materials.

[0095] Example 36 is an apparatus comprising: a prismatic cell battery package including: a casing forming an outer shell of the prismatic cell battery package, wherein: the casing includes, a battery enclosure and a top secured to the battery enclosure; and a valve port is disposed within the top of the casing, the valve port being configured to release gas within the casing in response to a pressure within the casing being at least a threshold pressure; and a plurality of battery electrodes disposed within the prismatic cell battery package.

[0096] In Example 37, the subject matter of Example 36 includes, wherein a fill port is located in the top of the casing and the valve port is located in conjunction with the fill port.

[0097] In Example 38, the subject matter of Examples 36-37 includes, wherein a vent port is located in the top of the casing and the valve port is located in conjunction with the vent port.

[0098] In Example 39, the subject matter of Examples 36-38 includes, wherein a fill portis located in a first location of the top of the casing and the valve port is located in a second location of the top of the casing.

[0099] In Example 40, the subject matter of Examples 36-39 includes, wherein a vent is located in a first location of the top of the casing and the valve port is located in a second location of the top of the casing.

[0100] In Example 41, the subject matter of Examples 36-40 includes, wherein a fill port is located in a first location of the top of the casing, a vent port is located in a second location of the top of the casing, and the valve port is located in a third location of the top of the casing.

[0101] In Example 42, the subject matter of Examples 36-41 includes, wherein the valve port comprises at least one of a spring-loaded ball, a gasket, a plunger, a check valve, or a diaphragm valve.

[0102] In Example 43, the subject matter of Example 42 includes, wherein the valve port includes the check valve and the check valve comprises a ball check valve, a swing check valve, a wafer check valve, a tilting disc check valve, a single leaf check valve, a double leaf check valve, a multihalf check valve, a nozzle check valve, a butterfly check valve, a lift check valve, or a one-way check valve.

[0103] In Example 44, the subject matter of Examples 36-43 includes, wherein the valve port includes a rupture disc that is configured to break at pressures from about 2000 kPa to about 5000 kPa.

[0104] Example 45 is an apparatus comprising means to implement of any of Examples 1-28.

Claims

CLAIMSWhat is claimed is:

1. A method comprising: providing a battery enclosure that includes a casing, the battery enclosure including a first section and a second section, wherein a plurality of lithium-ion battery electrodes are located in the first section and a port is located on a portion of the casing that corresponds to the second section; performing an initial charging process for the plurality of lithium-ion battery electrodes, wherein the initial charging process causes formation of one or more gases within the battery enclosure; causing the one or more gases to be released out of the battery enclosure through the port in response to a pressure within the battery enclosure being at least a threshold pressure; and after completion of the initial charging process and after the pressure within the battery enclosure is less than the threshold pressure, modifying the battery enclosure to produce a lithium- ion battery package.

2. The method of claim 1, wherein modifying the battery enclosure includes removing the second section of the battery enclosure.

3. The method of claim 2, wherein the second section of the battery enclosure is removed through a mechanical cutting process following by a heat sealing process.

4. The method of claim 2, wherein the second section of the battery enclosure is removed through a laser cutting process.

5. The method of claim 1, wherein the port includes a valve and modifying the battery enclosure includes replacing the valve with a rupture disc.

6. The method of claim 5, wherein the rupture disc is configured to break at an additional threshold pressure.

7. The method of claim 6, wherein the additional threshold pressure is from about 2000 kPa to about 5000 kPa.

8. The method of claim 1, wherein the port includes a valve and modifying the battery enclosure includes: removing the valve to form an opening; and sealing the opening.

9. The method of claim 1, wherein the threshold pressure is from about 3 kilopascals (kPa) to about 6 kPa.

10. The method of claim 1, wherein the first section is adjacent to the second section.

11. The method of claim 1, wherein modifying the battery enclosure includes forming a seal between the first section and a second section.

12. The method of claim 1, wherein an interface is disposed between the first section and the second section that enables the one or more gases generated in the first section to move into the second section.

13. The method of claim 12, wherein the interface includes a porous membrane comprised of one or more polymeric materials.

14. The method of claim 1, comprising: after performing the initial charging process, applying negative pressure to the battery enclosure to remove additional amounts of the one or more gases from the battery enclosure.

15. The method of claim 1, comprising: injecting an amount of electrolyte into the battery enclosure through the port.

16. The method of claim 1, wherein, before modifying the battery enclosure, the port includes a valve that closes in response to the pressure within the battery enclosure being less than the threshold pressure.

17. The method of claim 1, wherein the port includes a valve that comprises at least one of a spring-loaded ball, a gasket, a plunger, a check valve, or a diaphragm valve.

18. The method of claim 17, wherein the port includes the check valve and the check valve comprises a ball check valve, a swing check valve, a wafer check valve, a tilting disc check valve, a single leaf check valve, a double leaf check valve, a multi -half check valve, a nozzle check valve, a butterfly check valve, a lift check valve, or a one-way check valve.

19. The method of claim 1, wherein the battery enclosure is comprised of one or more metallic materials.

20. The method of claim 19, wherein the one or more metallic materials include at least one of aluminum, alloys of aluminum, nickel, alloys of nickel, or stainless steel.

21. The method of claim 1, wherein the battery enclosure is comprised of one or more polymeric materials.

22. The method of claim 1, wherein the lithium-ion battery package is a pouch cell.

23. The method of claim 1, wherein the lithium-ion battery package is a prismatic cell.

24. The method of claim 23, wherein the second section is a top that is secured to the battery enclosure.

25. The method of claim 1, wherein the battery enclosure has a first internal volume and the lithium-ion battery package has a second internal volume that is different from the first internal volume.

26. The method of claim 25, wherein the second internal volume of the lithium-ion battery package is at least 0.5 times less than the first internal volume of the battery enclosure.

27. The method of claim 25, wherein the second internal volume of the lithium-ion battery package is from about 200 cm3to about 1500 cm3.

28. The method of claim 25, wherein the first internal volume of the lithium-ion battery package is from about 500 cm3to about 2000 cm3.

29. An apparatus comprising: a pouch cell battery package including: a casing forming an outer shell of the pouch cell battery package, wherein a port is disposed within the casing, the port being configured to release gas within the casing in response to a pressure within the casing being at least a threshold pressure; and a plurality of battery electrodes disposed within the pouch cell battery package.

30. The apparatus of claim 29, wherein: the pouch cell battery package includes a first section and a second section adjacent to the first section; the plurality of battery electrodes are disposed in the first section; and the port is disposed in relation to the second section.

31. The apparatus of claim 30, wherein a boundary is disposed between the first section and the second section, the boundary including a porous polymeric material.

32. The apparatus of claim 29, wherein: the pouch cell battery package comprises a top surface, a bottom surface, and four side surfaces; and a seal is formed along a side surface of the four side surfaces.

33. The apparatus of claim 32, wherein the seal is formed along at least about 50% of the side surface.

34. The apparatus of claim 29, wherein the threshold pressure is from about 3 kPa to about 30 kPa.

35. The apparatus of claim 29, wherein the port is a seal of an opening in the casing and the seal is comprised of one or more metallic materials.

36. An apparatus comprising: a prismatic cell battery package including: a casing forming an outer shell of the prismatic cell battery package, wherein: the casing includes a battery enclosure and a top secured to the battery enclosure; and a valve port is disposed within the top of the casing, the valve port being configured to release gas within the casing in response to a pressure within the casing being at least a threshold pressure; and a plurality of battery electrodes disposed within the prismatic cell battery package.

37. The apparatus of claim 36, wherein a fill port is located in the top of the casing and the valve port is located in conjunction with the fill port.

38. The apparatus of claim 36, wherein a vent port is located in the top of the casing and the valve port is located in conjunction with the vent port.

39. The apparatus of claim 36, wherein a fill port is located in a first location of the top of the casing and the valve port is located in a second location of the top of the casing.

40. The apparatus of claim 36, wherein a vent is located in a first location of the top of the casing and the valve port is located in a second location of the top of the casing.41 . The apparatus of claim 36, wherein a fill port is located in a first location of the top of the casing, a vent port is located in a second location of the top of the casing, and the valve port is located in a third location of the top of the casing.

42. The apparatus of claim 36, wherein the valve port comprises at least one of a spring- loaded ball, a gasket, a plunger, a check valve, or a diaphragm valve.

43. The apparatus of claim 42, wherein the valve port includes the check valve and the check valve comprises a ball check valve, a swing check valve, a wafer check valve, a tilting disc check valve, a single leaf check valve, a double leaf check valve, a multi-half check valve, a nozzle check valve, a butterfly check valve, a lift check valve, or a one-way check valve.

44. The apparatus of claim 36, wherein the valve port includes a rupture disc that is configured to break at pressures from about 2000 kPa to about 5000 kPa.

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