Electrode foil coverings and methods thereof

Abstract

The present disclosure relates to an electrode assembly comprising an electrode and a coating layer or sleeve configured to be positioned over a bare region of an electrode, and methods of making the same. The coating layer or sleeve may reduce incidence of separator failure and / or internal short circuiting. The coating layer or sleeve may help reduce the stress caused by the edge of the electrode against another electrode. Energy storage devices, such as a lithium-ion battery, utilizing the electrode assembly are also described.

Description

TSLA.860WO PATENTELECTRODE FOIL COVERINGS AND METHODS THEREOFINCORPORATION BY REFERENCE TO ANY PRIORITY APPLICATIONS

[0001] Any and all applications for which a foreign or domestic priority claim is identified in the Application Data Sheet or PCT Request as filed with the present application are hereby incorporated by reference under 37 CFR 1.57, and Rules 4.18 and 20.6. This application claims the benefit of U.S. Provisional Application No. 63 / 692,592, filed on September 9, 2024, which is incorporated by reference herein in its entirety for all purposes.BACKGROUNDField

[0002] The present disclosure relates to energy storage devices and methods of making thereof. More specifically, the present disclosure relates to electrode assembly architectures and methods of making and using the same.Description of the Related Art

[0003] Many types of energy storage device (e.g., battery) cells are currently used as energy sources in electric vehicles and energy-storage applications. Many current cells use a jelly-roll design in which the cathode, anode, and separators are rolled together and have a cathode tab and an anode tab to connect to the positive and negative terminals of the cell can.

[0004] Energy storage devices are affected by component mechanical failures, which cause cell and / or product failure. In some instances, the edges and / or corners of an electrode concentrate mechanical stresses, which may be exacerbated by reversible and irreversible electrode volume expansion from charging and cell aging. Such mechanical stress concentration may lead to component mechanical failures, such as separator mechanical failure (e.g., wear-out, overloading, fatigue, creep, etc.) that can cause internal short circuiting. Additionally, exposed foil may contribute to internal short circuits within energy storage devices. As such, minimization of such stresses and / or short circuits in an energy storage device may be advantageous.SUMMARY

[0005] For purposes of summarizing the disclosure and the advantages achieved over the prior art, certain objects and advantages of the disclosure are described herein. Not all such objects or advantages may be achieved in any particular embodiment. Thus, for example, those skilled in the art will recognize that the invention may be embodied or carried out in a manner that achieves or optimizes one advantage or group of advantages as taught herein without necessarily achieving other objects or advantages as may be taught or suggested herein.

[0006] In some aspects, a method for manufacturing an electrode assembly is described. The method includes providing a multilane electrode including a plurality of electrode film lanes disposed over a foil and at least one bare foil region, where each of the electrode film lanes includes a tapered portion towards one of the at least one bare foil regions, where each electrode film lane is separated from each other by the bare foil region, applying a curable coating layer to the bare foil region and at least a portion of the tapered portion, curing the coating layer to form a cured coating layer, and thereby a coated multilane electrode, where the cured coating layer forms a chemically stable, electrochemically stable, and electronically insulating layer, and separating the coated multilane electrode to form a plurality of electrode assemblies.

[0007] In some aspects, a sleeve device for an electrode is disclosed. The sleeve device includes an external surface, an internal volume, an internal cavity positioned at least partially within the internal volume, and including a cavity opening, a taper end at a distal end of the sleeve device, a sleeve start end at a proximal end of the sleeve device, a tapered portion including the taper end and a taper start end proximal to the taper end, and an overlaying portion including a overlaying end adjacent to the taper start end and the sleeve start end, the cavity opening positioned at the sleeve start end, and the internal cavity, where the taper start end includes a first thickness and the taper end includes a second thickness, and the first thickness is greater than the second thickness.

[0008] In some embodiments, the external surface includes an insulating film. In some embodiments, the tapered portion and the overlaying portion are formed from a cured material. In some embodiments, the tapered portion includes a tapering gradient of about 0.1 to 20°.

[0009] In some aspects, an electrode assembly is disclosed. The electrode assembly includes a first electrode including an electrode end, and a sleeve device as described herein, and where the electrode end is positioned within the internal cavity.

[0010] In some aspects, a method for manufacturing an electrode assembly is disclosed. The method includes disposing a curable material over an insulating film, contacting an electrode end of an electrode with the curable material, shaping the insulating film and the curable material over the electrode end to form a tapered sleeve, and curing the curable material.

[0011] In some embodiments, the curable material includes a first component and a second component.

[0012] In some aspects, a method for manufacturing a coated electrode assembly is disclosed. The method includes providing a multilane electrode having a plurality of electrode film lanes disposed over a foil and separated from each other by a bare foil region, applying a coating layer to the bare foil region, curing the coating layer to form a cured coating layer, and processing the multilane electrode to form a plurality of coated electrode assemblies.

[0013] In some aspects, the coating includes a first component and a second component. In some aspects, the method includes shaping the coating and an insulating film sleeve into a tapered sleeve.

[0014] In some aspects, a method for manufacturing a coated electrode assembly is disclosed. The method includes providing a multilane electrode including a plurality of electrode film lanes disposed over a foil and at least one bare foil region, where each electrode film lane is separated from each other by the bare foil region, applying a coating layer to the bare foil region, curing the coating layer to form a cured coating layer, and thereby a coated multilane electrode, and separating the coated multilane electrode to form a plurality of coated electrode assemblies.

[0015] In some aspects, a coated electrode assembly is disclosed. The coated electrode assembly includes an electrode including an electrode film disposed over a first side of a foil and a bare foil region having an electrode end, and a coating layer disposed over the bare foil region.

[0016] In some embodiments, the electrode includes a second electrode film disposed over a second side of the foil. In some embodiments, the coating layer extends overa portion of the electrode film and a portion of the second electrode film. In some embodiments, the electrode includes a tapered portion. In some embodiments, the taper portion includes a first thickness towards the electrode end and a second thickness away from the electrode end, where the first thickness is less than or equal to the second thickness. In some embodiments, the coating layer includes a cured material. In some embodiments, the coating layer is selected from the group consisting of epoxy resin, an acrylate, a ceramic curable resin, and a silicone compound. In some embodiments, a sleeve device is disposed over the electrode end. In some embodiments, the coating layer includes a thickness less than or equal to 20 pm.

[0017] In some aspects, an energy storage device is disclosed. The energy storage device includes a coated electrode assembly as disclosed herein, a separator, a second electrode, and a housing, where the electrode assembly, the second electrode and the separator are disposed within the housing.

[0018] In some embodiments, the energy storage device is selected from the group consisting of a cylindrical energy storage device, a stacked prismatic energy storage device, and a spiral-wound prismatic energy storage device.

[0019] In one aspect, a sleeve device for an electrode is disclosed. The sleeve device comprises an external surface; an internal volume; an internal cavity positioned at least partially within the internal volume, and including a cavity opening; a taper end at a distal end of the sleeve device; a sleeve start end at a proximal end of the sleeve device; a tapered portion including the taper end and a taper start end proximal to the taper end; and an overlaying portion including a overlaying end adjacent to the taper start end and the sleeve start end, the cavity opening positioned at the sleeve start end, and the internal cavity. In some embodiments, the taper start end comprises a first thickness and the taper end comprises a second thickness. In some embodiments, the first thickness is greater than the second thickness.

[0020] In some embodiments, the external surface comprises an insulating film. In some embodiments, the insulating film extends beyond the sleeve start end of the overlaying portion of the sleeve device. In some embodiments, the insulating film has a thickness of about 5 pm to about 50 pm. In some embodiments, the insulating film comprises polypropylene (PP), polyethylene (PE), or combinations thereof. In some embodiments, the tapered portion and the overlaying portion are formed from a cured material. In some embodiments, the cured material comprises a cured polymer. In some embodiments, the cured polymer comprisespolyurea. In some embodiments, the cured material comprises a tensile strength of at least about 20 MPa. In some embodiments, the cured material comprises an elongation at break of at least about 50%. In some embodiments, the first thickness is about 0.1 mm to about 1 mm. In some embodiments, the second thickness is about 0.01 mm to about 0.1 mm. In some embodiments, the tapered portion comprises a tapering gradient of about 0.1 to 20°. In some embodiments, a length of the tapered portion from the taper start end to the taper end is about 0.5-10 mm.

[0021] In some embodiments, the taper start end of the tapered portion connects to the overlaying end of the overlaying portion. In another aspect, an electrode assembly is disclosed. The electrode assembly comprises a first electrode including an electrode end and a sleeve device. In some embodiments, the electrode end is positioned within the internal cavity. In some embodiments, the first electrode is a cathode. In some embodiments, the first electrode comprises an active layer disposed on one side of a current collector. In some embodiments, the first electrode comprises a second active layer disposed on the other side of the current collector.

[0022] In another aspect, an energy storage device is disclosed. The energy storage device comprises an electrode assembly, a separator, a second electrode; and a housing. In some embodiments, the electrode assembly, the second electrode and the separator are disposed within the housing. In some embodiments, the energy storage device is selected from the group consisting of a cylindrical energy storage device, a stacked prismatic energy storage device, and a spiral-wound prismatic energy storage device.

[0023] In another aspect, a method for manufacturing an electrode assembly is disclosed. The method comprises disposing a curable material over an insulating film; contacting an electrode end of an electrode with the curable material; shaping the insulating film and the curable material over the electrode end to form a tapered sleeve; and curing the curable material. In some embodiments, the curable material includes a first component and a second component. In some embodiments, the curing is performed for about 0.1 to about 10 seconds.

[0024] All of these embodiments are intended to be within the scope of the invention herein disclosed. These and other embodiments will become readily apparent to those skilled in the art from the following detailed description of the preferred embodimentshaving reference to the attached figures, the invention not being limited to any particular preferred embodiment(s) disclosed.BRIEF DESCRIPTION OF THE DRAWINGS

[0025] FIG. 1A illustrates a terminal end of an unrolled jellyroll with the anode electrode overhanging the cathode electrode, according to one embodiment.

[0026] FIG. IB illustrates a terminal end of an unrolled jelly roll with the anode electrode overhanging the cathode electrode and the anode current collector extending beyond the anode film, according to one embodiment.

[0027] FIG. 2 is a schematic drawing of a horizontal cross-section of a jellyroll design according to one embodiment.

[0028] FIG. 3 is an illustration and horizontal cross-sectional image of a stress point position at a terminal end of a jellyroll, according to one embodiment.

[0029] FIG. 4 is a side view illustration of a tapered electrode, according to one embodiment.

[0030] FIG. 5 is a side view illustration of a tapered and coated electrode assembly, according to an embodiment.

[0031] FIG. 6 is a side view illustration of a tapered and coated electrode assembly, according to an embodiment.

[0032] FIG. 7 is a side view illustration of a tapered and coated electrode assembly, according to an embodiment.

[0033] FIG. 8 is a top view illustration of a coated multilane electrode, according to an embodiment.

[0034] FIG. 9 schematically illustrates a cross-sectional side view of an electrode assembly according to some embodiments.

[0035] FIG. 10 illustrates a method of fabricating a coated electrode assembly according to some embodiments.

[0036] FIG. 11 schematically illustrates a process to fabricate a coated electrode assembly according to some embodiments.

[0037] FIG. 12 schematically illustrates a process to fabricate a coated electrode assembly according to some embodiments.

[0038] FIGS. 13 A and 13B show images of a sample electrolyte at room temperature and heated at 55°C.

[0039] FIGS. 13C and 13D show images of the cured material stored in a sample electrolyte according to some embodiments.

[0040] FIGS. 14A-14C are the images of a coated electrode assembly fabricated according to some embodiments.DETAILED DESCRIPTION

[0041] The present disclosure may be understood by reference to the following detailed description. It is noted that, for purposes of illustrative clarity, certain elements in various drawings may not be drawn to scale, may be represented schematically or conceptually, or otherwise may not correspond exactly to certain physical configurations of embodiments.

[0042] The present disclosure relates to electrode assemblies including a tapered electrode for use in an energy storage device having a sleeve device and a coated electrode assembly including a tapered electrode for use in an energy storage device having a coating.

[0043] In the electrode assembly including a tapered electrode for use in an energy storage device having a sleeve device, the tapered electrode includes a taper portion, and the electrode film (e.g., an active material) within the taper portion has a tapered thickness. In some embodiments, the taper portion includes a bare foil portion and a coating covering the bare foil portion. In some embodiments, the sleeve extends over a portion of the electrode film. In some embodiments, the tapered electrode with the taper portion may aid in reducing component stresses within an energy storage device, thereby preventing separator failure and / or internal short circuiting. In some embodiments, the taper portion may substantially bring stability to cell performance (e.g., prevent stress points and / or buckling) within the energy storage device. In some embodiments, the sleeve can prevent separator failure and / or internal short circuiting.

[0044] In the coated electrode assembly including a tapered electrode for use in an energy storage device having a coating, the tapered electrode includes a taper portion, and the electrode film (e.g., an active material) within the taper portion has a tapered thickness. In some embodiments, the taper portion includes a bare foil portion and a coating covering the bare foil portion. In some embodiments, the coating extends over a portion of the electrodefilm. In some embodiments, the tapered electrode with the taper portion may aid in reducing component stresses within an energy storage device, thereby preventing separator failure and / or internal short circuiting. In some embodiments, the taper portion may substantially bring stability (e.g., prevent stress points and / or buckling) to cell performance within the energy storage device. In some embodiments, the coating can prevent separator failure and / or internal short circuiting.

[0045] In some embodiments, a coated electrode assembly including a tapered electrode for use in an energy storage device including a tapered coating is described. The tapered coating can be positioned over a taper portion. In some embodiments, the taper portion includes a bare foil portion and the tapered coating covering the bare foil portion. In some embodiments, the coating extends over a portion of the electrode film. In some embodiments, the tapered electrode with the taper portion may aid in reducing component stresses within an energy storage device, thereby preventing separator failure and / or internal short circuiting. In some embodiments, the taper portion may substantially bring stability to cell performance within the energy storage device. In some embodiments, the coating can prevent separator failure and / or internal short circuiting.

[0046] In some embodiments, the electrode of the present disclosure includes a foil, an electrode film disposed over a first side of the foil, the electrode film including a first portion and a taper portion, where the taper portion includes a taper distal end and a taper proximal end adjacent to the first portion, where the electrode film within the first portion includes a first thickness, and the electrode film within the taper portion includes a tapering thickness less than the first thickness that reduces in thickness from the taper proximal end to the taper distal end. In some embodiments, the electrode film within the first portion includes a first thickness, and the electrode film within the taper portion includes the same first thickness.

[0047] In some embodiments, the terminal end of an unrolled jelly roll includes an anode and a cathode, and includes an anode overhanging portion, wherein the cathode is not disposed over the anode overhanging portion. For example, FIG. 1 A illustrates a terminal end of an unrolled jelly roll 100 with the anode electrode 104, anode tab 102 and the anode electrode edge 106 overhanging the cathode electrode 108 and the cathode electrode edge 110 by a distance 112. The anode electrode 104 overhangs the cathode electrode 108. Such an anode overhang remains when the jellyroll is wound such that the rolled anode overhang is notadjacent to the cathode. However, the abrupt termination of the electrode film disposed over the foil of the cathode may cause a stress point on the anode electrode, which may be exacerbated by cell charging and aging.

[0048] In another example, FIG. IB illustrates a terminal end of an unrolled jelly roll 120 with an anode electrode 122 and cathode electrode 124. The anode electrode 122 includes an anode electrode film 126, an anode electrode film edge 128 at a distal machine direction end of the anode electrode film 126, and an anode current collector 130 extending distally past the anode electrode film edge 128. The cathode electrode 124 includes a cathode electrode edge 132 at a distal machine direction end of the cathode electrode 124, wherein the anode electrode 122 overhangs the cathode electrode 124 in both transverse directions and the anode electrode film 126 overhangs the cathode electrode 124 by a distance 134 measured from the anode electrode film edge 128 to the cathode electrode edge 132.

[0049] In some embodiments, the tapered electrode may be used in an energy storage device with a jellyroll design. In energy storage devices with jelly roll designs, a separator layer is sandwiched between a layer of an anode and a layer of a cathode, and this sandwich is then rolled up and inserted into a hollow cylinder casing. For example, FIG. 2 illustrates a horizontal cross-section of a cell with a jellyroll design comprising an anode 202, a cathode 204, and a separator 206. In some embodiments, the terminal end of an unrolled jellyroll comprises an anode and a cathode, and includes an anode overhanging portion, wherein the cathode is not disposed over the anode overhanging portion. In some embodiments, FIG. 3 illustrates a horizontal cross-sectional image of a wound jellyroll with an overhang, which illustrates a stress point position 302 at a terminal end of a cathode of a jellyroll. The stress points would potentially lead to cell performance deviation. The abrupt termination of the electrode film disposed over the foil of the cathode may cause the stress point position 302 within the jelly roll and its constituent components (e.g., on the anode electrode), which may be exacerbated by cell charging and aging from usage. The stress points within the jelly roll and its constituent components (e.g., electrodes) may cause tearing of layers and / or a local buckling area of the electrodes, which may ultimately cause an internal short circuit (from separator mechanical failure) and subsequently cell and / or product failure.

[0050] Some embodiments of the present disclosure relate to an electrode including a foil, an electrode film disposed over a first side of the foil, and a first portion and a taperportion. In some embodiments, the taper portion includes a taper distal end and a taper proximal end adjacent to the first portion. In some embodiments, the electrode film within the first portion comprises a first thickness. In some embodiments, the electrode film within the taper portion comprises a tapering thickness less than the first thickness that reduces in thickness from the taper proximal end to the taper distal end.

[0051] In some embodiments, the electrode includes a bare portion including a bare distal end and a bare proximal end, and the electrode film is not disposed over the bare portion of the current collector. In some embodiments, the bare proximal end is adjacent to the taper distal end. By way of example, FIG. 4 is a side view illustration of a double-sided tapered electrode 400. The tapered electrode 400 includes a foil 401 (e.g., a current collector foil), an electrode film 402 disposed over a first side of the foil and extending from a first portion 403 and over a taper portion 404, and a bare portion 406. A second electrode film 407 is disposed over a second side of the foil and extends from the first portion 403 and over the taper portion 404. The second electrode film 407 can be substantially symmetrical to the first electrode film 402. The second side can also include a bare portion 406. The foil 401 includes a foil proximal end 408 and foil distal end 409. The electrode film 402 within the first portion 403 has a first thickness. The electrode film 402 within the taper portion 404 comprises a tapering thickness less than the first thickness that reduces in thickness from the taper proximal end 404a to the taper distal end 404b. The bare portion 406 includes a bare distal end 406b and a bare proximal end 406a, and the electrode film 402 is not disposed over the bare portion 406. The bare proximal end 406a is adjacent to the taper distal end 404b.

[0052] In some embodiments, the tapered portion comprises a tapering gradient of, of about, of at least, or of at least about, 0.1°, 0.2°, 0.3°, 0.4°, 0.5°, 0.6°, 0.7°, 0.8°, 0.9°, 1°,1.1°, 1.2°, 1.3°, 1.4°, 1.5°, 1.6°, 1.7°, 1.8°, 1.9°, 2°, 2.1°, 2.2°, 2.3°, 2.4°, 2.5°, 2.6°, 2.7°, 2.8°,2.9°, 3°, 4°, 5°, 6°, 7°, 8°, 9°, 10°, 11°, 12°, 13°, 14°, 15°, 16°, 17°, 18°, 19°, 20°, 21°, 22°, 23°, 24°, 25°, 26°, 27°, 28°, 29°, 30°, 31°, 32°, 33°, 34°, 35°, 36°, 37°, 38°, 39°, 40°, 41°, 42°, 43°, 44° or 45°, or any range of values therebetween. In some embodiments, the length of the taper portion from the taper proximal end to the taper distal end is, is about, is at least, or is at least about, 0.1 mm, 0.5 mm, 1 mm, 1.5 mm, 2 mm, 2.5 mm, 3 mm, 3.5 mm, 4 mm, 4.5 mm,5 mm, 5.5 mm, 6 mm, 6.5 mm, 7 mm, 7.5 mm, 10 mm, 15 mm, 20 mm, 25 mm, 30 mm, 35 mm, 40 mm, 45 mm, 50 mm, 55 mm or 60 mm, or any range of values therebetween. In someembodiments, the length of the plateau portion from the plateau proximal end to the plateau distal end is, is about, is at least, or is at least about, 0.1 mm, 0.2 mm, 0.3 mm, 0.4 mm, 0.5 mm, 0.6 mm, 0.7 mm, 0.8 mm, 0.9 mm, 1 mm, 1.1 mm, 1.2 mm, 1.3 mm, 1.4 mm, 1.5 mm,1.6 mm, 1.7 mm, 1.8 mm, 1.9 mm, 2 mm, 2.1 mm, 2.2 mm, 2.3 mm, 2.4 mm, 2.5 mm, 2.6 mm,2.7 mm, 2.8 mm, 2.9 mm, 3 mm, 3.1 mm, 3.2 mm, 3.3 mm, 3.4 mm, 3.5 mm, 3.6 mm, 3.7 mm,3.8 mm, 3.9 mm, 4 mm, 4.1 mm, 4.2 mm, 4.3 mm, 4.4 mm, 4.5 mm, 4.6 mm, 4.7 mm, 4.8 mm,4.9 mm, 5 mm, 5.1 mm, 5.2 mm, 5.3 mm, 5.4 mm, 5.5 mm, 5.6 mm, 5.7 mm, 5.8 mm, 5.9 mm,6 mm, 7 mm, 8 mm, 9 mm, 10 mm, 11 mm, 12 mm, 13 mm, 14 mm, 15 mm, 16 mm, 17 mm, 18 mm, 19 mm or 20 mm, or any range of values therebetween.

[0053] In some embodiments, a coating and / or tape is disposed over the tapered electrode to form a coated electrode assembly. In some embodiments, the tape or the coating is disposed over at least one of the first portion, the tapered portion, or the bare portion, or any combinations thereof. By way of example, FIG. 5 is a side view illustration of a coated electrode assembly 500 including a tapered electrode 502 with a taper portion 504 and a bare portion 506 extending beyond the taper portion 504, wherein a coating and / or tape 508A and 508B are positioned over the bare portion 506 and at least a portion of the taper portion 504. FIG. 6 is a side view illustration of a coated electrode assembly 500 including a tapered electrode 602 with a taper portion 604 and a bare portion 606 extending beyond the taper portion 604, wherein a coating and / or tape 608A and 608B are positioned over the bare portion 606.

[0054] FIG. 7 is a side view illustration of a coated electrode assembly 500 including a tapered electrode 702 including a foil 720 having an electrode film 710A on a first side and an electrode film 710B on a second side. The electrode films 710A and 710B include symmetrical tapers. A coating 730A is disposed over the taper of the electrode film 710A and a bare foil portion. A coating 730B is disposed over the taper of the electrode film 710B and a bare foil portion.

[0055] FIG. 8 illustrates a top view of a coated multilane electrode 800. The coated multilane electrode 800 includes a foil 820 having a first electrode film lane 810A separated a distance from a second electrode film lane 810B. The foil 820 between the first electrode film lane 810A and the second electrode film lane 810B forms a bare foil region and is covered by a coating layer 830. The coating layer 830 overlaps with the first electrode film lane 810A andthe second electrode film lane 810B. The coating 830 has a width W. The coating 830 has a length L.

[0056] In some embodiments, the coated multilane electrode 800 can include, include about, or include at least about 1, 2, 3, 4, 5, 6, 7, 8, 9, 10 or more electrode film lanes and foils. In some embodiments, the foil that is covered by the coating layer can be cut to separate each of coated electrode assemblies from one another. In some embodiments, the edges of the electrode film lanes have a tapered thickness, thereby forming a tapered portion. In some embodiments, the foils have a tapered thickness, thereby forming at least a portion of a tapered portion. In some embodiments, the coating layer can cover some or all of the tapered portion of the electrode film lanes and / or foils.

[0057] In some embodiments, the width W can be, be about, or be at least about 4 mm, 4.5 mm, 5 mm, 5.1 mm, 5.2 mm, 5.3 mm, 5.4 mm, 5.5 mm, 5.6 mm, 5.7 mm, 5.8 mm, 5.9 mm, 6 mm, 6.1 mm, 6.2 mm, 6.3 mm, 6.4 mm, 6.5 mm, 6.6 mm, 6.7 mm, 6.8 mm, 6.9 mm, 7 mm, 7.5 mm, 8 mm, or any range of values therebetween. In some embodiments, the length L can be, be about, or be at least about 50 mm, 55 mm, 56 mm, 57 mm, 58 mm, 59 mm, 60 mm, 61 mm, 62 mm, 63 mm, 64 mm, 65 mm, 66 mm, 67 mm, 68 mm, 69 mm, 70 mm, 71 mm, 72 mm, 73 mm, 74 mm, 75 mm, 80 mm, or any range of values therebetween. In some embodiments, the coating can include a thickness. In some embodiments, the thickness of the coating can be, be about, or be at most about, 1 pm, 2 pm, 3 pm, 4 pm, 5 pm, 6 pm, 7 pm, 8 pm, 9 pm, 10 pm, 11 pm, 12 pm, 13 pm, 14 pm, 15 pm, 16 pm, 17 pm, 18 pm, 19 pm, 20 pm, 30 pm, 40 pm, 50 pm, 60 pm, 70 pm, 80 pm, 90 pm, 100 pm, or any range of values therebetween.

[0058] In some embodiments, the coating can be a curable material, a glue, or combinations thereof. In some embodiments, the coating is a curable material. In some embodiments, the coating is a glue. In some embodiments, the coating includes two or more components. In some embodiments, the two or more components of the coating are stored separately to prevent reaction therebetween. In some embodiments, the two or more components of the coating may react when being mixed together and under curing conditions. In some embodiments, the coating includes a low viscosity that is capable of being dispensed, such as being sprayed, brushed, or dipped. In some embodiments, the coating includes a viscosity of, of about, of at most, of at most about, 50 cps, 100 cps, 200 cps, 300 cps, 400 cps,500 cps, 600 cps, 700 cps, 800 cps, 900 cps, 1000 cps, 1100 cps, 1200 cps, 1300 cps, 1400 cps, 1500 cps, 1600 cps, 1700 cps, 1800 cps, 1900 cps, 2000 cps, 2500 cps, 3000 cps, or any range of values therebetween. In some embodiments, the curable material can be an epoxy resin, an acrylate, polymers such as polyurethanes and polyureas, ceramic curable resins, silicone compounds, or combinations thereof. In some embodiments, the first component of the coating includes isocyanates and the second component of the coating includes amines. In some embodiments, the coating can be cured by mixing two components, cured by adding a curing agent, cured by heating, cured by adding light, for example UV light, cured by exposure to air, or combinations thereof. In some embodiments, the coating can be applied to the coated electrode in a liquid form. Advantageously, applying the coating in a liquid form can allow for the coating to form an ultra-thin (e.g., between 2 pm and 20 pm) coating having mechanically compliant properties and providing protection to the bare foil portion. In some embodiments, the coating can act as an insulator and prevent shorting. Advantageously, the coating can improve energy storage device safety by reducing risk of shorting due to contact between the bare foil and the anode and / or cathode once the energy storage device is formed. The coating thickness can advantageously reduce manufacturing failures because the thin coating has a low stiffness. Advantageously, the liquid coating can be applied efficiently and accurately. In some embodiments, the coating can be cured into a solid form after application. Advantageously, the cured coating has a strong adhesion, thereby firmly attaching to the electrode and covering the surface of the electrode. In some embodiments, the coating can be chemically and / or electrochemically stable once cured. In some embodiments, the coating can be stable against electrolyte soaking. In some embodiments, the coating can be brushed, dipped, or sprayed onto the coated electrode. In some embodiments, the coating can be a tape. In some embodiments, the coating and / or tape includes an insulating material (e.g., ceramic material and / or polymeric material). In some embodiments, the coating can be applied to the coated electrode before winding the electrode. In some embodiments, the electrode assembly includes a sleeve device including a cavity and an electrode having an electrode end positioned within the cavity of the sleeve device. In some embodiments, the sleeve device can be formed from tape, or a curable material disposed over the electrode assembly. In some embodiments, the sleeve device includes an external surface, an internal volume, and an internal cavity positioned at least partially within the internal volume. In some embodiments, the sleeve device includes a taperend at a distal end of the sleeve and a sleeve start end at a proximal end of the sleeve device. In some embodiments, the sleeve device includes a tapered portion having a taper end and a taper start end proximal to the taper end. The sleeve device can include an overlaying portion including an overlaying end adjacent to the taper start end and the sleeve start end. In some embodiments, the taper start end includes a first thickness and the taper end includes a second thickness that is smaller than the first thickness. In some embodiments, the tapered portion gradually reduces in thickness from the taper start end to the taper end. Advantageously, the sleeve device may aid in reducing component stresses within an energy storage device, thereby improving stability on cell performance. In some embodiments, the sleeve device may be formed from an insulating material. The insulating material may further separate the electrode from the other electrode at the electrode end in an energy storage device, which may further prevent the short circuiting. Moreover, the sleeve structure is capable of accommodating any shape of the electrode end, such that an electrode end having various shapes can be covered and protected using the sleeve structure and method disclosed herein.

[0059] By way of example, FIG. 9 is a side view illustration of a coated electrode assembly 900. The coated electrode assembly 900 includes an electrode 904 having an electrode end 904a, and a sleeve device 902. The sleeve device 902 including a tapered portion 921 and an overlaying portion 922. The sleeve device 902 includes a sleeve start end 922a and a taper end 921a at opposite ends of the sleeve device 902. The sleeve device 902 includes a width W3 of the distance from the sleeve start end 922a and the taper end 921a. The tapered portion 921 includes a taper start end 921b at one end of the tapered portion 921 and the taper end 921a at the opposite end of the tapered portion 921. The tapered portion 921 includes a width W2 from the taper start end 921b to the taper end 921a. The overlaying portion 922 includes an overlaying end 922b at one end of the overlaying portion 922 and the sleeve start end 922a at the opposite end of the overlaying portion 922. The overlaying portion 922 includes a width W 1 from the sleeve start end 922a to the overlaying end 922b. The overlaying end 922b of the overlaying portion 922 is adjacent and / or connects to the taper start end 921b of the tapered portion 921.

[0060] With continued reference to FIG. 9, the sleeve device 902 includes an external surface 908. The sleeve device 902 includes a cured material 906 positioned within the external surface 908. The external surface 908 includes an insulating film 914. Theinsulating film 914 is shown disposed over the tapered portion 921 and the overlaying portion 922. The insulating film 914 covers the entire surface of the overlaying portion 922 and the tapered portion 921 as illustrated. The insulating film 914 is shown extending beyond the sleeve start end 922a of overlaying portion 922. In some embodiments, the insulating film 914 includes a single film. The insulating film 914 has a thickness T3.

[0061] The sleeve device 902 further includes an internal volume having an internal cavity 912 positioned at least partially within the internal volume. The electrode end 904a of an electrode 904 is positioned within the internal cavity 912. The internal cavity 912 includes a cavity opening positioned at the sleeve start end 922a. The overlaying portion 922 surrounds the electrode end 904a. The electrode end 904a has a thickness T2, where thickness T2 is the same or substantially similar to the thickness of the cavity. The sleeve start end 922a of the overlaying portion 922 includes a thickness Tl. The overlaying end 922b includes a thickness T7. The overlaying portion 922 of the sleeve device 902 has a uniform or substantially uniform thickness distribution from the sleeve start end 922a to the overlaying end 922b, such that thickness Tl is the same or substantially the same as the thickness T7 of the overlaying end 922b.

[0062] With continued reference to FIG. 9, the taper end 921a of the tapered portion 921 includes a thickness T5 and the taper start end 921b includes a thickness T6. The thickness of the taper end T5 is less than the thickness of the taper start end T6, and the thickness of the tapered portion 921 reduces gradually from the taper start end 921b to the taper end 921a. The taper end 921a includes a taper end surface 910, and the taper end surface 910 is shown as a blunt surface with a curved shape. The tapered portion 921 includes a tapering gradient of the tapered portion 921 that is calculated by inverse tangent of (T6-T5) / W2.

[0063] With continued reference to FIG. 9, the overlaying portion 922 of the sleeve device 902 is configured to receive and / or surround the electrode end 904a. The distal end 922a of the overlaying portion 922 comprises a thickness Tl and the proximal end 922b includes a thickness T7. The overlaying portion 922 of the sleeve device 902 has a uniform or substantially uniform thickness distribution along the length of the electrode, such that the distal end thickness Tl is the same or substantially the same as the proximal end thickness T7 of the overlaying portion.

[0064] In some embodiments, the tapered portion comprises a tapering gradient of, of about, of at least, or of at least about, 0.1°, 0.2°, 0.3°, 0.4°, 0.5°, 0.6°, 0.7°, 0.8°, 0.9°, 1°,1.1°, 1.2°, 1.3°, 1.4°, 1.5°, 1.6°, 1.7°, 1.8°, 1.9°, 2°, 2.1°, 2.2°, 2.3°, 2.4°, 2.5°, 2.6°, 2.7°, 2.8°,2.9°, 3°, 4°, 5°, 6°, 7°, 8°, 9°, 10°, 11°, 12°, 13°, 14°, 15°, 16°, 17°, 18°, 19° or 20°, or any range of values therebetween. In some embodiments, the width W2 of the tapered portion from the taper start end to the taper end is, is about, is at least, or is at least about, 0.1 mm, 0.5 mm, 0.6 mm, 0.7 mm, 0.8 mm, 0.9 mm, 1 mm, 1.05 mm, 1.1 mm, 1.15 mm, 1.2 mm, 1.25 mm, 1.3 mm, 1.35 mm, 1.4 mm, 1.5 mm, 1.6 mm, 1.7 mm, 1.8 mm, 1.9 mm, 2 mm, 3 mm, 4 mm, 5 mm, or 10 mm, or any range of values therebetween. In some embodiments, the thickness T5 of the taper end is, is about, is at least, or is at least about, 0.01 mm, 0.02 mm, 0.03 mm, 0.04 mm, 0.05 mm, 0.06 mm, 0.07 mm, 0.08 mm, 0.09 mm, 0.1 mm, 0.11 mm, 0.12 mm, 0.13 mm, 0.15 mm, 0.16 mm, 0.17 mm, 0.18 mm, 0.19 mm, 0.2 mm, 0.5 mm, 1 mm, 5 mm, 10 mm, or any range of values therebetween. In some embodiments, the thickness T6 of the taper start end is, is about, is at least, or is at least about, 0.1 mm, 0.11 mm, 0.12 mm, 0.13 mm, 0.14 mm, 0.15 mm, 0.16 mm, 0.17 mm, 0.18 mm, 0.19 mm, 0.20 mm, 0.21 mm, 0.22 mm, 0.23 mm, 0.024 mm, 0.25 mm, 0.26 mm, 0.27 mm, 0.28 mm, 0.29 mm, 0.3 mm, 0.5 mm, 1 mm, 2 mm, 3 mm, 5 mm, 10 mm, or 15 mm, or any range of values therebetween. In some embodiments, the thickness T6 of the taper start end is, is about, is at most, is at most about, is at least, is at least about, 5%, 10%, 15%, 20%, 30%, 50%, 60%, 100%, 200%, 300%, 400%, 500%, 1000%, more than the thickness T5 of the taper end, or any range of values therebetween. In some embodiments, the tapered portion gradually reduces in thickness from the taper start end to the taper end. In some embodiments, the thickness of the electrode end T1 is, is about, is at most, is at most about, is at least, is at least about, 5%, 10%, 15%, 20%, 30%, 50%, 60%, 100%, 200%, 300%, 400%, 500%, 1000%, more than the thickness of the taper end, or any range of values therebetween.

[0065] In some embodiments, the width W1 of the overlaying portion from the sleeve, tape, and / or coating layer start end to the overlaying end is, is about, is at least, or is at least about, 0.1 mm, 0.5 mm, 0.6 mm, 0.7 mm, 0.8 mm, 0.9 mm, 1 mm, 1.05 mm, 1.1 mm, 1.15 mm, 1.2 mm, 1.25 mm, 1.3 mm, 1.35 mm, 1.4 mm, 1.5 mm, 1.6 mm, 1.7 mm, 1.8 mm, 1.9 mm, 2 mm, 3 mm, 4 mm, 5 mm, or 10 mm, or any range of values therebetween. In some embodiments, the overlaying portion has a uniform or substantially uniform thickness alongthe length of the overlaying portion. In some embodiments, the overlaying portion has a thickness Tl, T7 of, of about, of at least, or of at least about 0.1 mm, 0.11 mm, 0.12 mm, 0.13 mm, 0.14 mm, 0.15 mm, 0.16 mm, 0.17 mm, 0.18 mm, 0.19 mm, 0.20 mm, 0.21 mm, 0.22 mm, 0.23 mm, 0.024 mm, 0.25 mm, 0.26 mm, 0.27 mm, 0.28 mm, 0.29 mm, 0.3 mm, 0.5 mm, 1 mm, 2 mm, 3 mm, 5 mm, 10 mm, or 15 mm, or any range of values therebetween. In some embodiments, the thickness Tl of the overlaying end is less than the thickness T7 of the sleeve start end. In some embodiments, the thickness Tl of the overlaying end is, is about, is at most, is at most about, is at least, is at least about, 0.1%, 0.5%, 1%, 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9%, 10%, 15%, 20%, 30% less than the thickness T7 of the sleeve start end, or any range of values therebetween. In some embodiments, the thickness T7 of the overlaying end is similar or substantially similar to the thickness T6 of the taper start end.

[0066] In some embodiments, the insulating film can be any insulating film that has excellent wear resistance and chemical resistance. In some embodiments, the insulating film can be a tape. In some embodiments, the insulating film can be a coating layer as described herein. In some embodiments, the coating layer can be curable. In some embodiments, the insulating film can be the same film used as a separator of an energy storage device. For example, in some embodiments, the insulating film is selected from polypropylene (PP), and polyethylene (PE), polyamide and polyolefin, and combinations thereof. In some embodiments, the insulating film comprises 1, 2, 3, 4, 5, or 10 layers of insulating film, or any range of values therebetween. In some embodiments, the thickness of the insulating film is, is about, is at least, or is at least about, 1 pm, 5 pm, 6 pm, 7 pm, 8 pm, 9 pm, 10 pm, 11 pm, 12 pm, 13 pm, 14 pm, 15 pm, 16 pm, 17 pm, 18 pm, 19 pm, 20 pm, 50 pm, or 100 pm, or any range of values therebetween.

[0067] In some embodiments, the sleeve device is formed of an insulating material. In some embodiments, the cured material is a cured polymer. In some embodiments, the insulating material is configured to be formed by curing the corresponding monomers or oligomers. In some embodiments, the insulating material comprises a copolymer. In some embodiments, an insulating material having a high strength and a high elongation at break can be used for forming the sleeve. In some embodiments, the insulating material has a tensile strength of, of about, of at least, of at least about, 10 MPa, 15 MPa, 20 MPa, 25 MPa, 30 MPa, 35 MPa, 40 MPa, 50 MPa, 60 MPa, 70 MPa, 100 MPa, or any range of values therebetween.In some embodiments, the insulating material has a hardness of, of about, of at most, of at most about, 10 B 9 B, 8 B, 7 B, 6 B, 5 Bf4 B, 3 B. 2 B, 1 B, or any range of values therebetween. In some embodiments, the insulating material has a bending diameter of peeling film of, of about, of at least, or of at least about, 0.1 mms, 0.5 mms, 1 mms, 2 mms, 3 mms, 4 mms, 5 mms, 6 mms, 7 mms, 8 mms, 9 mms, 10 mms, or any range of values therebetween. In some embodiments, the insulating material has an energy storage modulus of, of about, of at least, of at least about, 1 MPa, 2 MPa, 3 MPa, 4 MPa, 5 MPa, 6 MPa, 7 MPa, 8 MPa, 9 MPa, 10 MPa, or any range of values therebetween. In some embodiments, the insulating material has an elongation at break at room temperature of, of about, of at least, of at least about, 10%, 20% 30%, 50%, 100%, or any range of values therebetween. In some embodiments, the insulating material comprises polyurea.Electrodes and Energy Storage Devices

[0068] The electrode disclosed herein may be used for an energy storage device, for example as used in an electric vehicle. In some embodiments, the energy storage device comprises one or more separators, an anode electrode, a cathode electrode, an electrolyte, and a housing, wherein the electrolyte, separator, anode electrode and cathode electrode are disposed within the housing and the separator is positioned between the anode and cathode electrodes. In some embodiments, an energy storage device is formed by placing an electrolyte, a separator, an anode electrode and the cathode electrode described herein within a housing, wherein the separator is placed between the anode electrode and the cathode electrode. In some embodiments, the energy storage device is a battery. In some embodiments, the energy storage device is a lithium-ion battery. In some embodiments, the energy storage device comprises an anode electrode positioned between two cathode electrodes.

[0069] An active material (e.g., cathode active material, anode active material) may be used in the preparation of an electrode film and / or electrode for an energy storage device. In some embodiments, an electrode comprises a current collector and an electrode film.

[0070] In some embodiments, the electrode film is or is substantially free of solvent residue. In some embodiments, the electrode film includes, includes about, includes at least, or includes at least about, 90 wt.%, 91 wt.%, 92 wt.%, 93 wt.%, 94 wt.%, 95 wt.%, 96 wt.%, 97 wt.%, 98 wt.% or 99 wt.%, or any range of values therebetween, of the active material.

[0071] In some embodiments, the active material is a cathode active material, an anode active material, or combinations thereof. In some embodiments, the cathode active material is selected from at least one of a metal oxide, metal sulfide, a sulfur-carbon composite, a lithium metal oxide, and a material including sulfur. In some embodiments, the cathode active material is selected from lithium iron phosphate (i.e., LiFePCh or “LFP”), lithium manganese iron phosphate (e.g., LiMno.6Feo.4PO4 or “LMFP”), lithium nickel manganese cobalt oxide (i.e., LiNixMnyCoi-x-yO2 or “NMC”), lithium nickel cobalt aluminum oxide (i.e., LiNixCoyAlzO2 or “NCA”), lithium manganese oxide (“LMO”), lithium nickel manganese oxide (“LNMO”), lithium cobalt oxide (“LCO”), lithium titanate (“LTO”), or combinations thereof. In some embodiments, the cathode active material includes at least two of LFP, LMFP, NMC, NCA, LMO, LNMO, LCO, LTO, and combinations thereof. In some embodiments, cathode active materials can comprise, for example, a metal oxide, metal sulfide, or a lithium metal oxide. The lithium metal oxide can be, for example, a lithium nickel manganese cobalt oxide (NMC), a lithium manganese oxide (LMO), a lithium iron phosphate (LFP), a lithium cobalt oxide (LCO), a lithium titanate (LTO), and / or a lithium nickel cobalt aluminum oxide (NCA). In some embodiments, cathode active materials can comprise, for example, a layered transition metal oxide (such as LiCoO2 (LCO), Li(NiMnCo)O2 (NMC) and / or LiNi0.8Co0.15Al0.05O2 (NCA)), a spinel manganese oxide (such as LiMmCU (LMO) and / or LiMm.5Nio.5O4 (LMNO)), an olivine (such as LiFePO4), chalcogenides (LiTiS2), tavorite (LiFeSO4F), silicon, silicon oxide (SiOx), aluminum, tin, tin oxide (SnOx), manganese oxide (MnOx), molybdenum oxide (MOO2), molybdenum disulfide (M0S2), nickel oxide (NiOx), and copper oxide (CuOx), or combinations thereof. The cathode active material can comprise sulfur or a material including sulfur, such as lithium sulfide (Li2S), or other sulfurbased materials, or a mixture thereof.

[0072] In some embodiments, anode active materials can include, for example, an insertion material (such as carbon, graphite, and / or graphene), an alloying / dealloying material (such as silicon, silicon oxide, tin, and / or tin oxide), a metal alloy or compound (such as Si-Al, and / or Si-Sn), and / or a conversion material (such as manganese oxide, molybdenum oxide, nickel oxide, and / or copper oxide). The anode active materials can be used alone or mixed together to form multi-phase materials (such as Si-C, Sn-C, SiOx-C, SnOx-C, Si-Sn, Si-SiOx, Sn-SnOx, Si-SiOx-C, Sn-SnOx-C, Si-Sn-C, SiOx-SnOx-C, Si-SiOx-Sn, or Sn-SiOx-SnOx).Anode active materials include common natural graphite, synthetic or artificial graphite, surface modified graphite, spherical-shaped graphite, flake-shaped graphite and blends or combinations of these types of graphite, metallic elements and its compound as well as metal- C composite for anode.

[0073] In some embodiments, the electrode film includes, includes about, includes at most, or includes at most about, 1 wt.%, 2 wt.%, 3 wt.%, 4 wt.%, 5 wt.%, 6 wt.%, 7 wt.%, 8 wt.%, 9 wt.%, 10 wt.%, or any range of values therebetween, of a binder. In some embodiments, the electrode film includes, includes about, includes at most, or includes at most about, 1 wt.%, 2 wt.%, 3 wt.%, 4 wt.%, 5 wt.%, 6 wt.%, 7 wt.%, 8 wt.%, 9 wt.%, 10 wt.%, or any range of values therebetween, of the binder. In some embodiments, the electrode film includes, includes about, includes at most, or includes at most about, 1 wt.%, 2 wt.%, 3 wt.%, 4 wt.% or 5 wt.% or any range of values therebetween, of the binder. In some embodiments, the binder (e.g., fluorinated binder, low surface energy binder) is selected from poly vinylidene fluoride (PVDF), polytetrafluoroethylene (PTFE), polyvinylfluoride (PVF), polychlorotrifluoroethylene (PCTFE), perfluoroalkoxy polymer (PF A), fluorinated ethylenepropylene (FEP), polyethylenetetrafluoroethylene (ETFE), polyethylenechlorotrifluoroethylene (ECTFE), perfluorinated elastomer, fluoroelastomer, perfluoropolyether (PFPE), polyethylene (PE), polypropylene (PP), poly(ethylene oxide) (PEO), poly(phenylene oxide) (PPO), polyethylene-block-poly(ethylene glycol), polydimethylsiloxane (PDMS), polydimethylsiloxane-coalkylmethylsiloxane, carboxymethylcellulose (CMC), co-polymers thereof and combinations thereof. In some embodiments, the binder (e.g., fluorinated binder, low surface energy binder) is selected from polyvinylidene fluoride (PVDF), polytetrafluoroethylene (PTFE), polyvinylfluoride (PVF), polychlorotrifluoroethylene (PCTFE), perfluoroalkoxy polymer (PF A), fluorinated ethylenepropylene (FEP), polyethylenetetrafluoroethylene (ETFE), polyethylenechlorotrifluoroethylene (ECTFE), perfluorinated elastomer, fluoroelastomer, perfluoropolyether (PFPE), co-polymers thereof and combinations thereof. In some embodiments, the electrode film includes, includes about, includes at most, or includes at most about, 0.1 wt.%, 0.5 wt.%, 1 wt.%, 2 wt.%, 3 wt.%, 5 wt.%, 8 wt.%, 10 wt.%, 15 wt.%, 20 wt.%, 25 wt.%, 30 wt.%, 40 wt.%, 50 wt.%, 60 wt.% or 70 wt.% of binder, or any range of values therebetween.

[0074] In some embodiments, an electrode film comprises a carbon material configured to reversibly intercalate lithium ions. In some embodiments, the electrode film comprises the carbon material in a total amount of, of about, of at most, or at most about, 20 wt.%, 15 wt.%, 10 wt.%, 9 wt.%, 8 wt.%, 7 wt.%, 6 wt.%, 5 wt.%, 4 wt.%, 3 wt.%, 2 wt.%, 1 wt.%, or any range of values therebetween. In some embodiments, the lithium intercalating carbon is selected from a graphitic carbon, graphite, hard carbon, soft carbon, and combinations thereof. For example, the electrode film of the electrode can include a binder material, one or more of graphitic carbon, graphite, graphene-containing carbon, hard carbon and soft carbon, and an electrical conductivity promoting material. In some embodiments, an electrode is mixed with lithium metal and / or lithium ions.

[0075] In some embodiments, an electrode film includes a conductive additive. In some embodiments, the conductive additive may comprise a conductive carbon additive. In some embodiments, the conductive carbon additive comprises a carbon black, carbon nanotubes, such as single-walled carbon nanotubes (SWCNTs) and multi-walled carbon nanotubes (MWCNTs). In some embodiments, the electrode film comprises the conductive additive in a total amount of, of about, of at most, or at most about, 10 wt.%, 9 wt.%, 8 wt.%, 7 wt.%, 6 wt.%, 5 wt.%, 4 wt.%, 3 wt.%, 2 wt.%, 1 wt.%, 0.5 wt.%, 0.25 wt.%, 0.1 wt.%, or any range of values therebetween. In some embodiments, each of the conductive additive is in an amount of, of about, of at most, or at most about, 10 wt.%, 9 wt.%, 8 wt.%, 7 wt.%, 6 wt.%, 5 wt.%, 4 wt.%, 3 wt.%, 2 wt.%, 1 wt.%, 0.5 wt.%, 0.25 wt.%, 0.1 wt.%, of the electrode film, or any range of values therebetween. In some embodiments, the conductive additive is carbon black.

[0076] In some embodiments, the electrode film comprises a thickness of, of about, of at most, or at most about, 1000 pm, 900 pm, 800 pm, 700 pm, 600 pm, 500 pm, 400 pm, 300 pm, 250 pm, 200 pm, 150 pm, 100 pm, 90 pm, 80 pm, 70 pm, 60 pm, 50 pm, 40 pm, 30 pm, 20 pm, 15 pm, 10 pm, or any range of values therebetween. In some embodiments, the electrode film may provide an active material loading (which may be expressed as mass of electrode film per unit area of electrode film or current collector) of, of about, of at least, of at least about 3 mg / cm2, 4 mg / cm2, 5 mg / cm2, 10 mg / cm2, 15 mg / cm2, 20 mg / cm2, 30 mg / cm2, 40 mg / cm2, 50 mg / cm2, 100 mg / cm2, or any range of values therebetween.

[0077] In some embodiments, the electrode film can be a wet processed electrode film. In some embodiments, the electrode film is prepared by a wet or slurry-based electrode fabrication process. In some embodiments, the electrode film of the present disclosure can be a dry processed electrode film. In some embodiments, the electrode film is prepared by a dry electrode fabrication process. As used herein, a dry electrode fabrication process can refer to a process in which no or substantially no solvents are used to form a dry electrode film. For example, components of the active layer or electrode film, including carbon materials and binders, may comprise, consist of, or consist essentially of dry particles. The dry particles for forming the active layer or electrode film may be combined to provide a dry particle active layer mixture. In some embodiments, the active layer or electrode film may be formed from the dry particle active layer mixture such that weight percentages of the components of the active layer or electrode film and weight percentages of the components of the dry particle active layer mixture are substantially the same. In some embodiments, the active layer or electrode film formed from the dry particle active layer mixture using the dry fabrication process may be free from, or substantially free from, any processing additives such as solvents and solvent residues resulting therefrom. In some embodiments, the resulting active layer or electrode films are self-supporting films formed using the dry process from the dry particle mixture. In some embodiments, the resulting active layer or electrode films are free-standing films formed using the dry process from the dry particle mixture. A process for forming an active layer or electrode film can include fibrillizing the fibrillizable binder component(s) such that the film comprises fibrillized binder. In further embodiments, a free-standing active layer or electrode film may be formed in the absence of a current collector. In still further embodiments, an active layer or electrode film may comprise a fibrillized polymer matrix such that the film is self-supporting. It is thought that a matrix, lattice, or web of fibrils can be formed to provide mechanical structure to the electrode film.

[0078] A “self-supporting” electrode film is an electrode film that incorporates binder matrix structures sufficient to support the film or layer and maintain its shape such that the electrode film or layer can be free-standing. When incorporated in an energy storage device, a self-supporting electrode film or active layer is one that incorporates such binder matrix structures. Generally, and depending on the methods employed, such electrode films or active layers are strong enough to be employed in energy storage device fabricationprocesses without any outside supporting elements, such as a current collector or other film. For example, a “self-supporting” electrode film can have sufficient strength to be rolled, handled, and unrolled within an electrode fabrication process without other supporting elements. A dry electrode film, such as a cathode electrode film or an anode electrode film, may be self-supporting.

[0079] In some embodiments, an electrode film is disposed on a current collector to form an electrode. In some embodiments, a current collector can include a metallic material, such as a material comprising aluminum, nickel, copper, combinations of the foregoing. In some embodiments, a current collector comprises a pure metal. In some embodiments, a current collector comprises a metallized polymer film or metal coated polymer film. In some embodiments, the polymer comprises polyethylene terephthalate (PET), biaxially oriented polypropylene (BOPP) or a combination thereof. In some embodiments, the metal coating comprises aluminum. In some embodiments, coating the final electrode film mixture comprises forming a uniform electrode film mixture coating. In some embodiments, the current collector comprises a thickness of, of about, of at most, or at most about, 200 pm, 100 pm, 50 pm, 40 pm, 30 pm, 20 pm, 15 pm, 10 pm, 5 pm, or any range of values therebetween.

[0080] In some embodiments, an electrode is a double-sided electrode. In some embodiments, the double-sided electrode includes two electrode films. In some embodiments, the double-sided electrode may include a current collector, a top electrode film, and a bottom electrode film. In some embodiments, each of the two electrode films can have any suitable shape, size and thickness.

[0081] In some embodiments, the energy storage device is charged with a suitable lithium-containing electrolyte. For example, the energy storage device can include a lithium salt, and a solvent, such as a non-aqueous or organic solvent. Generally, the lithium salt includes an anion that is redox stable. In some embodiments, the anion can be monovalent. In some embodiments, a lithium salt can be selected from lithium hexafluorophosphate (LiPFe), lithium bis(trifluoromethanesulfonyl)imide (LiFSI), lithium tetrafluoroborate (LiBF4), lithium perchlorate (LiClO-i), lithium bis(trifluoromethansulfonyl)imide (LiN(SO2CF3)2), lithium trifluoromethansulfonate (LiSChCFs), lithium bis(oxalato)borate (LiB(C2O4)2), lithium bis(fluorosulfonyl)imide (LiN(SO2F)2, lithium difluoro(oxalato)borate (LiC2BF2O4) and combinations thereof. In some embodiments, the electrolyte can include a quaternaryammonium cation and an anion selected from the group consisting of hexafluorophosphate, tetrafluoroborate and iodide. In some embodiments, the salt concentration can be about 0.1 mol / L (M) to about 5 M, about 0.2 M to about 3 M, or about 0.3 M to about 2 M. In further embodiments, the salt concentration of the electrolyte can be about 0.7 M to about 2 M. In certain embodiments, the salt concentration of the electrolyte can be about 0.2 M, about 0.3 M, about 0.4 M, about 0.5 M, about 0.6 M, about 0.7 M, about 0.8 M. about 0.9 M, about 1 M, about 1.1 M, about 1.2 M, 1.3M, 1.4M, 1.5M or values therebetween.

[0082] In some embodiments, an energy storage device can include a liquid solvent. The solvent need not dissolve every component, and need not completely dissolve any component, of the electrolyte. In further embodiments, the solvent can be an organic solvent. In some embodiments, a solvent can include one or more functional groups selected from dioxathiolane (e.g., l,3,2-dioxathiolane-2,2-dioxide (i.e., “DTD”)), carbonates, ethers and / or esters. In some embodiments, the solvent can comprise a carbonate. In further embodiments, the carbonate can be selected from cyclic carbonates such as, for example, ethylene carbonate (EC), propylene carbonate (PC), vinyl ethylene carbonate (VEC), vinylene carbonate (VC), fluoroethylene carbonate (FEC), and combinations thereof, or acyclic carbonates such as, for example, dimethyl carbonate (DMC), diethyl carbonate (DEC), ethyl methyl carbonate (EMC), and combinations thereof. In some embodiments, one or more solvents can be used at a concentration of, of about, of at least, or at least about, 30 wt. %, 35 wt. %, 40 wt. %, 45 wt. %, 50 wt. %, 55 wt. %, 60 wt. %, 65 wt. %, 70 wt. %, 75 wt. %, 80 wt. %, 85 wt. % or 90 wt. %, or any range of values therebetween. In some embodiments, solvents are utilized as additives in the electrolyte system, and can be used at a concentration of, of about, of at most, or at most about, 0.1 wt. %, 0.2 wt. %, 0.3 wt. %, 0.4 wt. %, 0.5 wt. %, 0.6 wt. %, 0.7 wt. %, 0.8 wt. %, 0.9 wt. %, 1 wt. %, 1.1 wt. %, 1.2 wt. %, 1.3 wt. %, 1.4 wt. %, 1.5 wt. %, 1.6 wt. %, 1.7 wt. %, 1.8 wt. %, 1.9 wt. %, 2 wt. %, 2.1 wt. %, 2.2 wt. %, 2.3 wt. %, 2.4 wt. %, 2.5 wt. %, 2.6 wt. %, 2.7 wt. %, 2.8 wt. %, 2.9 wt. %, 3 wt. %, 4 wt. %, 5 wt. %, 6 wt. %, 7 wt. %, 8 wt. %, 9 wt. % or 10 wt. %, or any range of values therebetween. For example, in some embodiments, the amount of an additive in the electrolyte is or is about in any one of the following ranges: 0.1-10 wt.%, 1-6 wt.%, 2-5 wt.%, 0.1-6 wt.%, 2-8 wt.%, 2-3 wt.%, or 1-4 wt.%.

[0083] In some embodiments, an energy storage device comprises a separator, an anode electrode, a cathode electrode, an electrolyte, and a housing, wherein the electrolyte, separator, anode electrode and cathode electrode are disposed within the housing and the separator is positioned between the anode and cathode electrodes. In some embodiments, an energy storage device is formed by placing an electrolyte, a separator, an anode electrode, and the cathode electrode described herein within a housing, wherein the separator is placed between the anode electrode and the cathode electrode. In some embodiments, the energy storage device is a battery. In some embodiments, the energy storage device is a lithium-ion battery.

[0084] In some embodiments, the energy storage device may comprise one or more separators. In some embodiments, the one or more separators is in the form of a laminate that has a pre-determined amount of thickness, for example, in the range of 1-50 pm. In some embodiments, the one or more separators, is about, is at least, or is at least about, 1 pm, 2 pm,3 pm, 4 pm, 5 pm, 6 pm, 7 pm, 8 pm, 9 pm, 10 pm, 15 pm, 20 pm, 30 pm, 40 pm or 50 pm, or any range of values therebetween (e.g. 5-10 gm). Furthermore, in some embodiments, the one or more separators is electrically insulative. In some embodiments, the one or more separators may comprise a polymeric material. In some embodiments, the one or more separators may be selected from polyethylene, polypropylene, or combinations thereof. In some embodiments, the one or more separators comprise multiple separator layers. In some embodiments, the one or more separators comprise micro-pores. In some embodiments, the one or more separators are enabled at a temperature of, of about, of at most, or of at most about,15°C, 16°C, 17°C, 18°C, 19°C, 20°C, 21 °C, 22°C, 23°C, 24°C, 25°C, 26°C, 27°C, 28°C, 29°C or 30°C, or any range of values therebetween. In some embodiments, the one or more separators are adhered or bonded to an electrode film.

[0085] In some embodiments, an energy storage device is created such that one electrode (e.g., anode) is larger than and overhangs the other electrode (e.g., cathode). One electrode may overhang the other in the winding direction and / or non-winding direction of the electrode assembly. Such electrode overhangs may avoid yield losses. In some embodiments where there is no, or is substantially no, overlap and / or intermingling of the separator and the shaped electrode film (e.g., cathode electrode film), the boundary of the shaped electrode filmis easier to identify and therefore improves the ability to form a counter electrode (e.g., anode electrode) with an overhang.

[0086] In some embodiments, the energy storage device comprises a cell core of, of about, of at most, or at most about, 1 mm, 2 mm, 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, 10 mm, 11 mm or 12 mm, or any range of values therebetween.

[0087] The electrode disclosed herein may be used for an energy storage device. In some embodiments, the energy storage device comprises a separator, an anode electrode, the cathode electrode, an electrolyte, and a housing, wherein the electrolyte, separator, anode electrode and cathode electrode are disposed within the housing and the separator is positioned between the anode and cathode electrodes. In some embodiments, an energy storage device is formed by placing an electrolyte, a separator, an anode electrode and the cathode electrode described herein within a housing, wherein the separator is placed between the anode electrode and the cathode electrode. In some embodiments, the energy storage device comprises an anode electrode positioned between two cathode electrodes. In some embodiments, the anode electrode and / or the cathode electrode comprises a shaped electrode film. In some embodiments, the energy storage device is a lithium-ion battery. In some embodiments, the energy storage devices may be a battery, capacitor, capacitor-battery hybrid, fuel cell, or combinations thereof. In some embodiments, the energy storage system or energy storage device may be used for electromobility. In some embodiments, the energy storage device may be used in motor vehicles, including hybrid electric vehicles (HEV), plug-in hybrid electric vehicles (PHEV), and / or electric vehicles (EV). In some embodiments, the energy storage device used in motor vehicles, including hybrid electric vehicles (HEV), plug-in hybrid electric vehicles (PHEV), and / or electric vehicles (EV) reduces greenhouse gas emissions.

[0088] In some embodiments, the energy storage device is selected from the group consisting of a cylindrical energy storage device, a stacked prismatic energy storage device, and a spiral-wound prismatic energy storage device. An energy storage device as provided herein can be of any suitable configuration, for example planar, spirally wound, button shaped, or pouch. In some embodiments, the cathode, anode, and separators disposed over one another are rolled together to form a jelly-roll design. In some embodiments, the coating substantially prevents stresses and shorting within the electrode.Methods for Manufacturing

[0089] Some embodiments of the present disclosure relate to a process for preparing embodiments of electrode assemblies, for example, the electrode assemblies disclosed herein. As an example, FIG. 10 illustrates a method 1000 for preparing coated electrode assemblies. The method 1000 includes a step 1010 of providing a multilane electrode having a plurality of electrode film lanes disposed over a foil and separated from each other by a bare foil region. At step 1020, the method 1000 includes applying a coating layer to the bare foil region. At step 1030, the method 1000 includes curing the coating layer to form a cured coating layer. At step 1040, the method 1000 includes processing the multilane electrode to form a plurality of coated electrode assemblies.

[0090] Some embodiments of the present disclosure relate to a process for preparing embodiments of electrode assemblies and / or coated electrode assemblies, for example, the electrode assemblies and coated electrode assemblies disclosed herein. As an example, FIG. 11 illustrates the process 1100 for preparing the electrode assembly. The process 1100 includes dispensing a curable material over an insulating film 1102. In some embodiments, the curable material is a UV curable and / or a heat curable material. In some embodiments, the curable material includes two or more components. In some embodiments, the two or more components of the curable material are stored separately to prevent reaction therebetween. In some embodiments, the two or more components of the curable material may react when being mixed together and under curing conditions. In some embodiments, dispensing a curable material over the insulating film includes dispensing a first component over the insulating film and then a second component over the insulating film. In some embodiments, before dispensing the curable material over the insulating film, the separate components of the curable material are mixed and then applied over the insulating film. In some embodiments, the curable material includes a low viscosity that is capable of being dispensed, such as being sprayed, onto the insulating film. In some embodiments, the curable material includes a viscosity of, of about, of at most, of at most about, 50 cps, 100 cps, 200 cps, 300 cps, 400 cps, 500 cps, 600 cps, 700 cps, 800 cps, 900 cps, 1000 cps, 1100 cps, 1200 cps, 1300 cps, 1400 cps, 1500 cps, 1600 cps, 1700 cps, 1800 cps, 1900 cps, 2000 cps, 2500 cps, 3000 cps, or any range of values therebetween. In some embodiments, the first componentof the curable material includes isocyanates and the second component of the curable material includes amines.

[0091] The process 1100 includes contacting the electrode end with the curable material 1104. In some embodiments, alternatively, the electrode end is placed onto the insulating film before dispensing the curable material. In some embodiments, the curable material is dispensed over the electrode end after the electrode end is placed onto the insulating film. The properties and types of curable material may be the same as in Step 1102.

[0092] With continued reference to FIG. 11, the process 1100 includes curing the curable material to form a cured material 1106. In some embodiments, curing the curable material includes curing with a UV light and / or heat for a period of time to fully or substantially fully polymerize the curable material. In some embodiments, the curing time is, is about, is at most, is at most about, 0.1 seconds, 0.2 seconds, 0.3 seconds, 0.4 seconds, 0.5 seconds, 0.6 seconds, 0.7 seconds, 0.8 seconds, 0.9 seconds, 1 seconds, 2 seconds, 3 seconds, 4 seconds, 5 seconds, 6 seconds, 7 seconds, 8 seconds, 9 seconds, 10 seconds, 15 seconds, 20 seconds, or 30 seconds, or any range of values therebetween. In some embodiments, the curing 1106 is performed with heating. In some embodiments, heating the curable material while curing reduces the curing time.

[0093] Optionally, the process 1100 includes shaping the cured material and the insulating film with the electrode into a tapered sleeve 1108. In some embodiments, the shaping 1108 includes molding, such as hot molding, thermoforming, compression molding, or combinations thereof. Alternatively, the step of shaping 1108 may be performed before the step of curing 1106. In some embodiments, the electrode assembly and / or coated electrode assembly is formed and can be used in fabricating an energy storage device.

[0094] In some embodiments, the process for manufacturing the electrode assembly is performed as least partially automatically by a machine, such that no manual efforts are needed between at least two steps. For example, the amount of the first component and the second component of the curable material is automatically weighed and dispensed onto the insulating film, the nozzle for dispensing the curable material is automatically cleaned after dispensing each component, the UV light is automatically applied to the curable material with a set time automatically after the shaping step and / or the shaping are automatically performed after curing.

[0095] FIG. 12 illustrates the process 1200 for preparing a coated electrode assembly. The process 1200 includes dispensing a coating over an electrode end 1202. In some embodiments, the coating can be a curable material, a glue, or combinations thereof. In some embodiments, the coating is a curable material. In some embodiments, the coating is a UV curable and / or a heat coating. In some embodiments, the coating includes two or more components. In some embodiments, the two or more components of the coating are stored separately to prevent reaction therebetween. In some embodiments, the two or more components of the coating may react when being mixed together and under curing conditions. In some embodiments, the coating includes a low viscosity that is capable of being dispensed, such as being sprayed, brushed, or dipped. In some embodiments, the coating includes a viscosity of, of about, of at most, of at most about, 50 cps, 100 cps, 200 cps, 300 cps, 400 cps, 500 cps, 600 cps, 700 cps, 800 cps, 900 cps, 1000 cps, 1100 cps, 1200 cps, 1300 cps, 1400 cps, 1500 cps, 1600 cps, 1700 cps, 1800 cps, 1900 cps, 2000 cps, 2500 cps, 3000 cps, or any range of values therebetween. In some embodiments, the curable material can be an epoxy resin, an acrylate, polymers such as polyurethanes and polyureas, ceramic curable resins, silicone compounds, or combinations thereof. In some embodiments, the first component of the coating includes isocyanates and the second component of the coating includes amines. In some embodiments, the coating can be cured by mixing two components, cured by adding a curing agent, cured by heating, cured by adding light, for example UV light, cured by exposure to air, or combinations thereof. In some embodiments, the coating can be applied to the coated electrode assembly in a liquid form. Advantageously, applying the coating in a liquid form can allow for the coating to form an ultra-thin (e.g., between 2 pm and 20 pm) coating having mechanically compliant properties and providing protection to the bare foil portion. In some embodiments, the coating can act as an insulator and prevent shorting. Advantageously, the coating can improve energy storage device safety by reducing risk of shorting due to contact between the bare foil (e.g., bare current collector) and the anode and / or cathode once the energy storage device is formed. The coating thickness can advantageously reduce stresses and manufacturing failures because the think coating has a low stiffness. Advantageously, the liquid coating can be applied efficiently and accurately. In some embodiments, the coating can be cured into a solid form after application. Advantageously, the cured coating has a strong adhesion, thereby firmly attaching to the electrode and covering the surface of the electrode.In some embodiments, the coating can be chemically and / or electrochemically stable once cured. In some embodiments, the coating can be stable against electrolyte soaking. In some embodiments, the coating can be brushed, dipped, or sprayed onto the coated electrode. In some embodiments, the coating can be a tape. In some embodiments, the coating and / or tape includes an insulating material (e.g., ceramic material and / or polymeric material).

[0096] The process 1200 includes applying the coating to the electrode end 1204. In some embodiments, the coating can be brushed, dipped, or sprayed onto the electrode end 1204. The properties and types of coating may be the same as in Step 1102.

[0097] With continued reference to FIG. 12, the process 1200 includes curing the coating to form a cured material 1206. In some embodiments, curing the coating includes curing with a UV light and / or heat for a period of time to fully or substantially fully polymerize the coating. In some embodiments, the curing time is, is about, is at most, is at most about, 0.1 seconds, 0.2 seconds, 0.3 seconds, 0.4 seconds, 0.5 seconds, 0.6 seconds, 0.7 seconds, 0.8 seconds, 0.9 seconds, 1 seconds, 2 seconds, 3 seconds, 4 seconds, 5 seconds, 6 seconds, 7 seconds, 8 seconds, 9 seconds, 10 seconds, 15 seconds, 20 seconds, or 30 seconds, or any range of values therebetween. In some embodiments, the curing 1206 is performed with heating. In some embodiments, heating the coating while curing reduces the curing time.

[0098] Optionally, the process 12 includes shaping the cured material and the insulating film with the electrode into a tapered sleeve 1208. In some embodiments, the shaping 1208 includes molding, such as hot molding, thermoforming, compression molding, or combinations thereof. Alternatively, the step of shaping may be performed before the step of curing 1206. In some embodiments, the coated electrode assembly is formed and can be used in fabricating an energy storage device.

[0099] In some embodiments, the process for manufacturing the coated electrode assembly is performed as least partially automatically by a machine, such that no manual efforts are needed between at least two steps. For example, the amount of the first component and the second component of the coating is automatically weighed and dispensed onto the insulating film, the nozzle for dispensing the coating is automatically cleaned after dispensing each component, the UV light is automatically applied to the coating with a set time automatically after the shaping step and / or the shaping are automatically performed after curing.EXAMPLES

[0100] Electrode assemblies and coated electrode assemblies of the present disclosure may be prepared utilizing the methods disclosed herein. Additional embodiments are disclosed in further detail in the following examples, which are not in any way intended to limit the scope of the claims.Example 1 - Stability and Properties of Cured Material

[0101] FIG. 13 A is an image of two jars of the same electrolyte stored at room temperature (right side) and at 55°C (left side). FIG. 13B is an image of the back side of the jars of electrolyte in FIG. 13 A, where the electrolyte on the left was stored at 55°C and the electrolyte on the right was stored at room temperature. FIG. 13C is an image of two jars of the same electrolyte, each containing a cured material stored at room temperature for 14 days. FIG. 13D is an image of the back side of the jars of electrolyte in FIG. 13C. In the Example, to create the samples illustrated in FIGS. 13A-13D, in dry room with moisture control, a glue sample having a set volume was manually dropped onto a clean glass substrate. UV light was applied to the glue to cure for 1 minute. Then, the cured glue block was peeled from the glass substrate and placed in ajar containing an electrolyte inside a glove box. The jar was closed with a cap and stored in the glove box for observation. The electrolytes in FIGS. 13A-13D are clear liquids, and no color change was observed, which shows that the cured material was stable in the electrolyte. In addition, Table 1 illustrates the properties of the fresh cured material, which shows that the cured material is suitable for the application of forming the sleeve for the electrode.TABLE 1Example 2 - Fabrication of Sleeve Device

[0102] FIG. 9 illustrates a design of an electrode assembly including a sleeve intended to be fabricated. The unit used is mm. FIGS. 14A-14C show the images of the electrode assembly fabricated with the method disclosed herein based on the design of FIG. 9. FIGS. 14A-14C show that the sleeve device has a tapered portion and an overlaying portion. The overlaying portion has a cavity and the electrode end is disposed in the cavity. The overlaying portion substantially surrounds the electrode end. FIG. 14A shows that the taper end of the tapered portion has a thickness of about 0.08 mm, FIG. 14B shows that the taper start end of the tapered portion has a thickness of about 0.26 mm, FIG. 14C shows that the tapered portion has a length of about 1.17 mm from the taper start end to taper end, which all match with the intended dimension of the sleeve.

[0103] In the foregoing specification, the disclosure has been described with reference to specific embodiments. However, as one skilled in the art will appreciate, various embodiments disclosed herein can be modified or otherwise implemented in various other ways without departing from the spirit and scope of the disclosure. Accordingly, this description is to be considered as illustrative and is for the purpose of teaching those skilled in the art the manner of making and using various embodiments of the disclosed battery system. It is to be understood that the forms of disclosure herein shown and described are to be taken as representative embodiments. Equivalent elements, or materials may be substituted for those representatively illustrated and described herein. Moreover, certain features of the disclosure may be utilized independently of the use of other features, all of which is apparent to one skilled in the art after having the benefit of this description of the disclosure. Expressions such as "including", "comprising", "incorporating", "consisting of, "have", "is" used to describe and claim the present disclosure are intended to be construed in a non-exclusive manner, namely allowing for items, components or elements not explicitly described also to be present. Reference to the singular is also to be construed to relate to the plural.

[0104] Further, various embodiments disclosed herein are to be taken in the illustrative and explanatory sense and should in no way be construed as limiting of the presentdisclosure. All joinder references (e.g., connected, associated, coupled, and the like) are only used to aid the reader's understanding of the present disclosure, and may not create limitations, particularly as to the position, orientation, or use of the elements disclosed herein. Therefore, joinder references, if any, are to be construed broadly. Moreover, such joinder references may not necessarily infer that two elements are directly connected to each other.

[0105] Additionally, all numerical terms, such as, but not limited to, "first", "second", "one", "another", or any other ordinary and / or numerical terms, should also be taken only as identifiers, to assist the reader's understanding of the various elements, embodiments, variations and / or modifications of the present disclosure, and may not create any limitations, particularly as to the order, or preference, of any element, embodiment, variation and / or modification relative to, or over, another element, embodiment, variation and / or modification.

[0106] It will also be appreciated that one or more of the elements depicted in the drawings / figures can also be implemented in a more separated or integrated manner, or even removed in certain cases, as is useful in accordance with a particular application.

[0107] For expository purposes, the term “horizontal” as used herein is defined as a plane parallel to the plane or surface of the floor of the area in which the device being described is used or the method being described is performed, regardless of its orientation. The term “floor” can be interchanged with the term “ground.” The term “vertical” refers to a direction perpendicular to the horizontal as just defined. Terms such as “above,” “below,” “bottom,” “top,” “side,” “front,” “rear,” “lateral,” “higher,” “lower,” “upper,” “over,” and “under,” are defined with respect to the horizontal plane, in use.

[0108] The terms “comprising,” “including,” “having,” and the like are synonymous and are used inclusively, in an open-ended fashion, and do not exclude additional elements, features, acts, operations, and so forth. Also, the term “or” is used in its inclusive sense (and not in its exclusive sense) so that when used, for example, to connect a list of elements, the term “or” means one, some, or all of the elements in the list.

[0109] Although certain embodiments and examples have been described herein, it will be understood by those skilled in the art that many aspects of the systems shown and described in the present disclosure may be differently combined and / or modified to form still further embodiments or acceptable examples. All such modifications and variations are intended to be included herein within the scope of this disclosure. A wide variety of designsand approaches are possible. No feature, structure, or step disclosed herein is essential or indispensable.

[0110] For purposes of this disclosure, certain aspects, advantages, and novel features are described herein. It is to be understood that not necessarily all such advantages may be achieved in accordance with any particular embodiment. Thus, for example, those skilled in the art will recognize that the disclosure may be embodied or carried out in a manner that achieves one advantage or a group of advantages as taught herein without necessarily achieving other advantages as may be taught or suggested herein.

[0111] Moreover, while illustrative embodiments have been described herein, the scope of any and all embodiments having equivalent elements, modifications, omissions, combinations (e.g., of aspects across various embodiments), adaptations and / or alterations as would be appreciated by those in the art based on the present disclosure. The limitations in the claims are to be interpreted broadly based on the language employed in the claims and not limited to the examples described in the present specification or during the prosecution of the application, which examples are to be construed as non-exclusive. Further, the actions of the disclosed processes and methods may be modified in any manner, including by reordering actions and / or inserting additional actions and / or deleting actions. It is intended, therefore, that the specification and examples be considered as illustrative only, with a true scope and spirit being indicated by the claims and their full scope of equivalents.

[0112] Conditional language used herein, such as, among others, “can,” “might,” “may,” “e.g.,” and the like, unless specifically stated otherwise, or otherwise understood within the context as used, is generally intended to convey that some embodiments include, while other embodiments do not include, certain features, elements, and / or states. Thus, such conditional language is not generally intended to imply that features, elements, blocks, and / or states are in any way required for one or more embodiments or that one or more embodiments necessarily include logic for deciding, with or without author input or prompting, whether these features, elements and / or states are included or are to be performed in any particular embodiment.

[0113] The ranges disclosed herein also encompass any and all overlap, sub-ranges, and combinations thereof. Language such as “up to,” “at least,” “greater than,” “less than,” “between,” and the like includes the number recited.

Claims

WHAT IS CLAIMED IS:

1. A method for manufacturing an electrode assembly, comprising: providing a multilane electrode comprising a plurality of electrode film lanes disposed over a foil and at least one bare foil region, wherein each of the electrode film lanes includes a tapered portion towards one of the at least one bare foil regions, wherein each electrode film lane is separated from each other by the at least one bare foil region; applying a curable coating layer to the at least one bare foil region and at least a portion of the tapered portion; curing the curable coating layer to form a cured coating layer, and thereby a coated multilane electrode, wherein the cured coating layer forms a chemically stable, electrochemically stable, and electrically insulating layer; and separating the coated multilane electrode to form a plurality of electrode assemblies.

2. A sleeve device for an electrode, comprising: an external surface; an internal volume; an internal cavity positioned at least partially within the internal volume, and comprising a cavity opening; a taper end at a distal end of the sleeve device; a sleeve start end at a proximal end of the sleeve device; a tapered portion comprising the taper end and a taper start end proximal to the taper end; and an overlaying portion comprising a overlaying end adjacent to the taper start end and the sleeve start end, the cavity opening positioned at the sleeve start end, and the internal cavity; wherein the taper start end comprises a first thickness and the taper end comprises a second thickness, and the first thickness is greater than the second thickness.

3. The sleeve device of Claim 2, wherein the external surface comprises an insulating film.

4. The sleeve device of any one of Claims 2 or 3, wherein the tapered portion and the overlaying portion are formed from a cured material.

5. The sleeve device of any one of Claims 2-4, wherein the tapered portion comprises a tapering gradient of about 0.1 to 20°.

6. An electrode assembly, comprising: a first electrode comprising an electrode end; and the sleeve device of any one of Claims 2-5; wherein the electrode end is positioned within the internal cavity.

7. A method for manufacturing an electrode assembly, comprising: disposing a curable material over an insulating film; contacting an electrode end of an electrode with the curable material; shaping the insulating film and the curable material over the electrode end to form a tapered sleeve; and curing the curable material.

8. The method of Claim 7, wherein the curable material comprises a first component and a second component.

9. A method for manufacturing a coated electrode assembly, comprising: providing a multilane electrode having a plurality of electrode film lanes disposed over a foil and separated from each other by a bare foil region; applying a coating layer to the bare foil region; curing the coating layer to form a cured coating layer; and processing the multilane electrode to form a plurality of coated electrode assemblies.

10. The method of Claim 9, wherein the coating layer comprises a first component and a second component.

11. The method of Claim 9, further comprising shaping the coating layer and an insulating film sleeve into a tapered sleeve.

12. A method for manufacturing a coated electrode assembly, comprising: providing a multilane electrode comprising a plurality of electrode film lanes disposed over a foil and at least one bare foil region, wherein each electrode film lane is separated from each other by the at least one bare foil region;applying a coating layer to the at least one bare foil region; curing the coating layer to form a cured coating layer, and thereby a coated multilane electrode; and separating the coated multilane electrode to form a plurality of coated electrode assemblies.

13. A coated electrode assembly, comprising: an electrode comprising an electrode film disposed over a first side of a foil and a bare foil region having an electrode end; and a coating layer disposed over the bare foil region.

14. The coated electrode assembly of Claim 13, wherein the electrode comprises a second electrode film disposed over a second side of the foil.

15. The coated electrode assembly of Claim 14, wherein the coating layer extends over a portion of the electrode film and a portion of the second electrode film.

16. The coated electrode assembly of any one of Claims 13-15, wherein the electrode comprises a tapered portion.

17. The coated electrode assembly of Claim 16, wherein the tapered portion comprises a first thickness towards the electrode end and a second thickness away from the electrode end, wherein the first thickness is less than or equal to the second thickness.

18. The coated electrode assembly of any one of Claims 13-17, wherein the coating layer comprises a cured material.

19. The coated electrode assembly of any one of Claims 13-18, wherein the coating layer is selected from the group consisting of epoxy resin, an acrylate, a ceramic curable resin, and a silicone compound.

20. The coated electrode assembly of any one of Claims 13-19, further comprising a sleeve device disposed over the electrode end.

21. The coated electrode assembly of any one of Claims 13-20, wherein the coating layer comprises a thickness less than or equal to 20 pm.

22. An energy storage device, comprising: the coated electrode assembly of any one of Claims 13-21; a separator; a second electrode; anda housing, wherein the coated electrode assembly, the second electrode and the separator are disposed within the housing.

23. The energy storage device of Claim 22, wherein the energy storage device is selected from the group consisting of a cylindrical energy storage device, a stacked prismatic energy storage device, and a spiral-wound prismatic energy storage device.

Images