Post-winding support inserts for energy storage devices, and methods thereof

Abstract

A post-winding support insert for an energy storage device is described. The post-winding support insert is inserted into the inner diameter surface of the wound electrode assembly and then activated to contact the inner diameter surface, thereby supporting the inner diameter surface in order to extend the life and / or performance of the energy storage device.

Description

TSLA.886WO PATENTPOST-WINDING SUPPORT INSERTS FOR ENERGY STORAGE DEVICES, ANDMETHODS THEREOFINCORPORATION BY REFERENCE TO ANY PRIORITY APPLICATIONS

[0001] Any and all applications for winch 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 / 701,196, filed on September 30, 2024, which is incorporated by reference herein in its entirety for all purposes.BACKGROUND

[0002] Many types of energy storage devices (e.g., batteries) are currently used in electric vehicles and energy-storage applications. Many energy storage devices use a ’’jellyroll” design in which the cathode, anode, and separator are wound or rolled together to form an electrode assembly, and connected to the positive and negative terminals of the energy storage device housing. Generally, winding processes may result in geometric imperfections (e.g., a natural kink, weak point, stress point, and / or electrode buckling zone) impacting the circularity of the final electrode assembly, which in turn may affect the lifetime of the energy storage device. For example, electrode buckling within the inner diameter of the ’’jellyroll” can lead to lithium plating, performance degradation, shorting and / or thermal run away.

[0003] As such, improving electrode assembly circularity and preventing electrode buckling with the inner diameter of a “jelly roll” may be beneficial.SUMMARY

[0004] 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.

[0005] 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 embodiments having reference to the attached figures, the invention not being limited to any particular preferred embodiment(s) disclosed.

[0006] In one aspect, a post-winding support insert for an energy storage device is described. The post-winding support insert includes an actuating body. In another aspect, a method of supporting the center of a wound electrode assembly is described. The method includes: providing a wound electrode assembly comprising an anode, a cathode and a separator, wherein the separator is disposed between the anode and the cathode, and wherein the wound electrode assembly is wound about a central axis to form an inner diameter surface surrounding a cylindrical void; inserting a non-actuated support insert within the cylindrical void; and activating the non-actuated support insert to form an actuated support insert substantially in contact with the inner diameter surface.

[0007] In another aspect, a method of supporting the center of a wound electrode assembly is described. The method includes: providing a wound electrode assembly comprising an anode, a cathode and a separator, w'herein the separator is disposed between the anode and the cathode, and wherein the wound electrode assembly is wound about a central axis to form a inner diameter surface surrounding a cylindrical void; inserting a support insert within the cylindrical void; and activating the support insert to reduce a diameter of the inner diameter surface such that the support insert is substantially in contact with the inner diameter surface.

[0008] In another aspect, a method of supporting the center of an energy storage device is described. The method includes: providing a wound electrode assembly comprising an anode, a cathode and a separator, wherein the separator is disposed between the anode and the cathode, and wherein the wound electrode assembly is wound about a central axis to form a inner diameter surface surrounding a cylindrical void; inserting a support insert within the cylindrical void; inserting the wound electrode assembly within a housing to form an energy storage device; and cycling the energy storage device such that the wound electrode assembly swells and the support insert is substantially in contact with the inner diameter surface.

[0009] In some aspects, an energy storage device is described. The energy storage device includes a can, a wound electrode assembly including an anode, a cathode and a separator, where the separator is disposed between the anode and the cathode, and where the wound electrode assembly is wound about a central axis to form an inner diameter surface surrounding a cylindrical void, the wound electrode assembly disposed interior to the can, the post-winding support insert including a radial spring including a coiled body having a plurality of layers, a start positioned at an inner diameter surface of the radially coiled body and an end positioned at an outer diameter of the radially coiled body, where the post-winding support insert is positioned against the inner diameter surface of the wound electrode assembly, and a lid positioned over the can.

[0010] In some embodiments, the wound electrode assembly is wound clockwise from an anode start outward and the post-winding support insert is wound clockwise from the anode start outward. In some embodiments, the wound electrode assembly is wound clockwise from an anode start outward and the post-winding support insert is wound counter-clockwise from the anode start outward. In some embodiments, the post- winding support insert comprises a material selected from stainless steel, aluminum, and combinations thereof. In some embodiments, the stainless steel is selected from a group consisting of 301 SS, 304 SS, 316 SS, and combinations thereof. In some embodiments, the post-winding support insert is floating relative to the can.

[0011] In some aspects, an energy storage device is described. The energy storage device includes a can, a wound electrode assembly including an anode, a cathode and a separator, where the separator is disposed between the anode and the cathode, and where the wound electrode assembly is wound about a central axis to form an inner diameter surface surrounding a cylindrical void, the wound electrode assembly disposed interior to the can, and a post-winding support insert positioned interior to the inner diameter surface of the wound electrode assembly, where the post-winding support insert includes an isolator positioned against a first end of the post-winding support insert.

[0012] In some embodiments, the post-winding support insert includes a tube. In some embodiments, the post-winding support insert includes a swell material. In some embodiments, the energy storage device further includes a second isolator positioned against a second end of the post-winding support insert. In some embodiments, the post-windingsupport insert includes a swell tape material positioned around an outer diameter of the tube. In some embodiments, the swell tape material is configured to swell when in contact with an electrolyte. In some embodiments, an outer diameter of the post-winding support insert is within 0.5 mm or less of the inner diameter surface of the wound electrode assembly. In some embodiments, the post- winding support insert is coupled with low thermal resistance to the can.

[0013] In some aspects an energy storage device is described. The energy storage device includes a can, a wound electrode assembly including an anode, a cathode and a separator, where the separator is disposed between the anode and the cathode, and where the wound electrode assembly is wound about a central axis to form an inner diameter surface surrounding a cylindrical void, the wound electrode assembly disposed interior to the can, and a post-winding support insert positioned interior to the inner diameter surface of the wound electrode assembly, where the post-winding support insert is coupled with low thermal resistance to the can.

[0014] In some embodiments, the energy storage device further includes a lid, where the lid is connected to the post-winding support insert.

[0015] In some aspects a method of supporting a center of a wound electrode assembly is described. The method including providing the wound electrode assembly including an anode, a cathode and a separator, where the separator is disposed between the anode and the cathode, and where the wound electrode assembly is wound about a central axis to form an inner diameter surface surrounding a cylindrical void, inserting a non-actuated support insert within the cylindrical void, and activating the non-actuated support insert to form an actuated support insert substantially in contact with the inner diameter surface.

[0016] In some embodiments, the non-actuated support insert includes a radial spring including a coiled body having a plurality of layers, a start positioned at an inner diameter surface of the radially coiled body and an end positioned at an outer diameter of the radially coiled body. In some embodiments, the method further includes inserting the wound electrode assembly within a housing to form an energy storage device, where activating the non-actuated support insert to form the actuated support insert substantially in contact with the inner diameter surface includes cycling the energy storage device such that the wound electrode assembly swells. In some embodiments, inserting the non-actuated support insertwithin the cylindrical void includes positioning the non-actuated support insert in a collet of an installation apparatus including a collet holder engaged with the collet, and a push pin which extends through the collet, and pushing the non-actuated support insert via the push pin against a pin stopper.BRIEF DESCRIPTION OF THE DRAWINGS

[0017] FIG. 1A is a schematic illustration showing a horizontal cross-section of an energy storage device, according to some embodiments.

[0018] FIG. IB is a schematic illustration showing a side view of an energy storage device and a support insert, according to some embodiments.

[0019] FIG. 2 is a flowchart showing the assembly of an energy storage device with a post-winding support insert, according to some embodiments.

[0020] FIG. 3A is a schematic illustration showing a horizontal cross-section of an electrode assembly with a radial coil support insert, according to some embodiments.

[0021] FIG. 3B is a schematic illustration showing a horizontal cross-section of a radial coil support insert in a non-activated and activated configurations, according to some embodiments.

[0022] FIG. 4A is a schematic illustration showing a top perspective view of a wound radial coil support insert, according to some embodiments.

[0023] FIG. 4B is an image showing a top perspective view of a wound radial coil support insert, according to some embodiments.

[0024] FIG. 5 is a schematic illustration showing a top view of an unwound radial coil support insert, according to some embodiments.

[0025] FIG. 6 / X is a schematic illustration showing a top view of an unwound radial coil support insert with an isolator, according to some embodiments.

[0026] FIG. 6B is a schematic illustration showing a side view of an unwound radial coil support insert with an isolator, according to some embodiments.

[0027] FIG. 7A is a schematic illustration showing a top view of an unwound laminated radial coil support insert, according to some embodiments.

[0028] FIG. 7B is a schematic illustration showing a side view' of an unwound laminated radial coil support insert, according to some embodiments.

[0029] FIG. 8A is a schematic illustration showing half of a vertical cross-section of an electrode assembly with a wound radial coil support and an insertion device within the inner diameter, according to some embodiments.

[0030] FIG. 8B is a schematic illustration showing a vertical cross-section of an electrode assembly with a wound radial coil support and an insertion device within the inner diameter, according to some embodiments.

[0031] FIG. 8C is a schematic illustration showing half of a vertical cross-section of an electrode assembly with an activated wound radial coil support within the inner diameter, according to some embodiments.

[0032] FIG. 9 is a schematic illustration showing exploded side perspective views of an energy storage device with a radial coil support, according to some embodiments.

[0033] FIG. 10A is a schematic illustration showing half of a vertical cross-section of an electrode assembly with a die forming support and an insertion device within the inner diameter, according to some embodiments.

[0034] FIG. 10B is a schematic illustration showing half of a vertical cross-section of an electrode assembly with an activated die forming support within the inner diameter, according to some embodiments.

[0035] FIG. H A is a schematic illustration showing a vertical cross-section of an electrode assembly with a die forming support being activated by a ball forming die, according to some embodiments.

[0036] FIG. 1 I B is a schematic illustration showing a vertical cross-section of an energy storage device with a die forming support including a vent / debris trap being activated by a ball forming die, according to some embodiments.

[0037] FIG. 12 is a schematic illustration showing a vertical cross-section of a die forming support being activated by a progressive forming die, according to some embodiments.

[0038] FIG. 13 A is a schematic illustration showing exploded side perspective views of an energy storage device with a lid die forming support, according to some embodiments.

[0039] FIG. 13B is a schematic illustration showing exploded side perspective views of an energy storage device with a floating die forming support, according to some embodiments.

[0040] FIG. 14A is a schematic illustration showing half of a vertical cross-section of an electrode assembly with a telescoping support and an insertion device within the inner diameter, according to some embodiments.

[0041] FIG. 14B is a schematic illustration showing half of a vertical cross-section of an electrode assembly with an activated telescoping support within the inner diameter, according to some embodiments.

[0042] FIG. 14C is a schematic illustration showing exploded side perspective views of an energy storage device with a telescoping support, according to some embodiments.

[0043] FIG. 14D is a schematic illustration showing a vertical cross-section of a telescoping support being activated, according to some embodiments.

[0044] FIG. 15A is a schematic illustration showing half of a vertical cross-section of an electrode assembly with a boring support and an insertion device within the inner diameter, according to some embodiments.

[0045] FIG. 15B is a schematic illustration showing half of a vertical cross-section of an electrode assembly with an activated boring support within the inner diameter, according to some embodiments,

[0046] FIG. 16A is a schematic illustration showing an exploded side perspective view of an energy storage device with a boring support, according to some embodiments.

[0047] FIG. 16B is a schematic illustration showing a horizontal cross-section of an electrode assembly with an activated boring support, according to some embodiments.

[0048] FIG. 17A is a schematic illustration showing a top view of a portion of a lock spring support, according to some embodiments.

[0049] FIG. 17B is a schematic illustration showing a top view of a portion of an activated lock spring support within an electrode assembly, according to some embodiments.

[0050] FIG. 18A is a schematic illustration showing half of a vertical cross-section of an electrode assembly with a lock spring support and an insertion device within the inner diameter, according to some embodiments.

[0051] FIG. 18B is a schematic illustration showing half of a vertical cross-section of an electrode assembly with an activated lock spring support within the inner diameter, according to some embodiments.

[0052] FIG. 19 is a schematic illustration showing a top view of a portion of a retaining ring support, according to some embodiments.

[0053] FIG. 20A is a schematic illustration showing half of a vertical cross-section of an electrode assembly with a retaining ring support and an insertion device within the inner diameter, according to some embodiments.

[0054] FIG. 20B is a schematic illustration showing half of a vertical cross-section of an electrode assembly with an activated retaining ring support within the inner diameter, according to some embodiments.

[0055] FIG. 21 is an image showing a horizontal cross-section of an electrode assembly with a material fill support within the inner diameter, according to some embodiments.

[0056] FIG. 22 is a schematic illustration showing a side view' of cable spiral support, according to some embodiments.

[0057] FIG. 23 A is a schematic illustration showing half of a vertical cross-section of an electrode assembly with a cable spiral support and an insertion device within the inner diameter, according to some embodiments.

[0058] FIG. 23B is a schematic illustration showing half of a vertical cross-section of an electrode assembly with an activated cable spiral support within the inner diameter, according to some embodiments.

[0059] FIG. 24 is a schematic illustration showing a top view' of a swelling support, according to some embodiments.

[0060] FIG. 25 is a schematic illustration showing a horizontal cross-section of an electrode assembly with a loose tube support, according to some embodiments.

[0061] FIG. 26A is a schematic illustration showing half of a vertical cross-section of an energy storage device with a loose support within the inner diameter, according to some embodiments.

[0062] FIG. 26B is a schematic illustration showing half of a vertical cross-section of a swelled energy storage device with a loose support in contact with the inner diameter, according to some embodiments.

[0063] FIG. 27 is a schematic illustration showing a perspective view of an energy storage device including a lid rivet support insert, according to some embodiments.DETAILED DESCRIPTION

[0064] 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.

[0065] In order to support the inner diameter of a previously wound electrode assembly (e.g., “j ellyroll” (i.e., “JR”)) and / or a cylindrical energy storage device once formed, a post-winding support may be inserted with the inner diameter (i.e., “ID”) and then activated to achieve intimate contact and / or support with the inner diameter. In some embodiments, such intimate contact and / or support by the activated post-winding support may improve or aid in improving the circularity of the electrode assembly. In some embodiments, intimate contact by the post- winding insert with the inner diameter is achieved prior to operating the energy storage device (e.g., formation cycle, swelling). The post-winding supports may be activated and / or installed to achieve contact with the inner diameter while maintaining axial location (e.g., Z position) in a tight tolerance environment, reducing assembly complexity, and / or reducing the number of parts in the cell. Such an activated post- winding support may support or aid in providing structural support to the inner diameter of the electrode assembly, and may prevent or aid in preventing electrode buckling as the cell swells due to cell cycling. Therefore, the post-winding support may prevent or aid in preventing lithium plating, performance degradation, shorting and / or thermal run away during the lifetime of the energystorage device.

[0066] Furthermore, in some embodiments, the post-winding support enables or aids in improved electrode assembly circularity, thermal transfer from the center of cell (e.g., passive and / or active thermal transfer within or out of the center of the cell), maintains a thermal runaway gas egress chimney (e.g., the inner diameter is clear of debris), increasedstiffness at inner diameter and / or allows for compliance or flexibility during cell swelling. In some embodiments, the post-winding support enables or aids in assembly of the energy storage device, for example such as welding of the electrode assembly to the energy storage device housing terminals (e.g., lid, housing current collector).

[0067] Further, in some embodiments, the post-winding support can function as a thermal conduit (e.g., support pathway). In some embodiments, the post-winding support can be connected (e.g., mechanically and / or thermally connected) to the can and / or lid (e.g., having a low thermal resistance), creating an efficient heat path from the core of the energy storage device to the can. The post-winding support can conduct thermal energy at and / or near the inner diameter of the wound electrode assembly to the can and therefore to the outer surface of the energy storage device. The post-winding support can thereby improve the cooling (e.g., cooling efficiency) and internal temperature gradients of the energy storage device. Advantageously, improving the cooling and internal temperature gradients of the energy storage device can increase the life and performance of the energy storage device.

[0068] In some embodiments, as an electrode assembly swells, the post-winding insert continues to contact the inner diameter and provide structural support while simultaneously being flexible and compliant enough to allow for swelling to occur. In some embodiments, the post- winding support is configured to decrease in diameter (e.g., rotate, furl) while the electrode assembly is swelling and increase in diameter (e.g., release the support, unfurl) when the electrode assembly is shrinking. In some embodiments, this ratcheting behavior may help the electrode assembly achieve a tight fit with the post-winding support as the electrode assembly swells. In some embodiments, if the post-winding support is rotated and / or spiraled, the post-winding support is positioned so the post-winding support does not enter into or in between layers of the electrode assembly. For example, in some embodiments the post-winding support contacts or only contacts the separator layer and / or anode layer of the electrode assembly. In some embodiments, the post-winding support does not contact the cathode layer.

[0069] In some embodiments, the post-winding support is configured to allow for inspection of the inner diameter after installation of the post-winding support. In some embodiments, the post-winding insert support does not damage and / or deform (e.g., telescope,bunch, buckle, tear, separate, delaminate) a layer(s) of the electrode assembly, including the anode, cathode and / or separator.

[0070] FIGS. 1A and IB are schematic illustrations showing an energy storage device 100, where a wound electrode assembly (e.g., a ‘jellyroll”) 104 is positioned within a can 106 and a post- winding insert 102 is positioned within the inner diameter of the wound electrode assembly 104. FIG. 2 is a flowchart showing a method of assembling a wound electrode assembly (e.g., a “jellyroll”, “JR”) with a post-winding support insert wherein the post-winding support insert is inserted into the inner diameter (“ID”), activated by actuation to contact the inner diameter and thereby support the wound electrode assembly through the end of life (“EOL”) of the energy storage device. At step 202 the method, the wound electrode assembly is located and oriented before installation. At step 204, a support (e.g., a post-winding support insert) is guided and translated (e.g., guided axially and / or guided along a z-axis) into position. At step 206, the depth of the support (e.g., the post- winding support insert) is secured at the correct depth (e.g., axial and / or z-position). At step 208, the support (e.g., the postwinding support insert) is activated which places the support (e.g., the post-winding support insert) in intimate contact with the inner diameter of the wound electrode assembly. At step 210, the support (e.g., the post-winding support insert) supports the wound electrode assembly through swelling.Assembly

[0071] The post-wind support is positioned or inserted within the inner diameter of the electrode assembly after the electrode assembly is wound. In some embodiments, a postwind support is positioned in the inner diameter before and / or after the electrode assembly is positioned within the housing, the housing is filled with electrolyte, the electrode assembly is electrically connected to the housing, lid(s) and / or tab(s), or combinations thereof. In some embodiments, the post-winding support is positioned within the inner diameter with the aid of an insertion device, wherein the insertion device is removed after insertion. In some embodiments, the inner diameter of the electrode assembly is processed prior to insertion of the post-winding support, for example such as moving and / or heating the separator, anode and / or cathode layers.Materials

[0072] The material(s) of the post- winding support insert may be selected to provide a balance between stiffness and compliance, to be compatible with the activation method, to resist degradation and contamination during operation, and / or operate throughout or substantially throughout the lifetime of the energy storage device. The material may include a metal, an alloy, a polymer material, a ceramic material, an epoxy material, a silicone material, or combinations thereof. In some embodiments, the metal or alloy is selected from stainless steel, low' carbon steel, copper, aluminum, alloys thereof, or combinations thereof. In some embodiments, the metal or alloy is selected from a stainless steel (e.g., 301 SS, 304 SS, 316 SS) and / or aluminum. Advantageously, in some embodiments, a post- winding support insert can improve electrolyte wetting. In some embodiments, the polymer material is selected from a plastic, a thermoplastic, an elastomer, a thermoplastic elastomer, and combinations thereof. In some embodiments, the polymer material is a polyethylene terephthalate (PET), a polyimide (PI), co-polyniers thereof, and combinations thereof. In some embodiments, the material is coated with a coating material. In some embodiments, the material and / or the coating is a swelling material that expands upon contact with a liquid (e.g., electrolyte). In some embodiments, the post- winding support insert is formed from a swelling material which can be activated and expanded when exposed to a liquid (e.g., electrolyte). In some embodiments, the material is a conductive material and / or an insulating material. In some embodiments, the material is corrosion resistant.

[0073] In some embodiments, the post-winding support insert and / or material is selected to make electrical contact with the anode and operate at the anode voltages and / or potential without or without substantial degradation, for example such as copper and stainless steel. In some embodiments, the post-winding support insert is in direct electrical contact with the anode. In some embodiments, the post-winding support insert and / or material is selected to make electrical contact with the cathode and operate at the cathode voltages and / or potential without or without substantial degradation, for example such as stainless steel. In some embodiments, the post-winding support insert is in direct electrical contact with the cathode. In some embodiments, the post-winding support insert and / or material is inert. In some embodiments, the post-winding support insert and / or material is selected to not make direct electrical contact with the cathode or anode and operate at a floating potential without orwithout substantial degradation. In some embodiments, the post-winding support insert is not in direct electrical contact with the anode or cathode.Activation Mechanisms and Example Post-Winding Support Inserts

[0074] In some embodiments, activation of the post-winding support may be performed by actuation of the post- winding insert. In some embodiments, example activation mechanisms include radial compliance activation, expanding activation, chemical activation, gravity^ activation, friction activation, temperature activation, and combinations thereof. In some embodiments, activating the post-winding support includes placing the post-winding support in intimate contact with the inner diameter of a wound electrode assembly' and creating a radial force to support the wound electrode assembly' through expansion of the post-winding support.

[0075] In some embodiments, radial compliance activation includes removal of a collar constraint from the post- wind support and / or removing (e.g., dissolving) of an adhesive in the post-wind support. In some embodiments, post-wind supports utilizing radial compliance activation include a radial coil support insert, lock spring support insert, a retaining ring support insert, a buckled support insert, a spiral cable support insert, and combinations thereof.

[0076] In some embodiments, expanding activation includes radial deformation (e.g., plastic deformation) of the post-wind support. In some embodiments, post-wind supports utilizing expanding activation include a die forming support insert, a telescoping support insert, a lock spring support insert, a stent support insert, a balloon reforming support insert, a compressed cylinder insert, an accordion inset, and combinations thereof.

[0077] In some embodiments, chemical activation includes a chemical reaction, liquid absorption and / or chemical bonding (e.g., ionic, covalent and / or hydrogen bonding) by the post-winding support. In some embodiments, post-wind supports utilizing chemical activation include a swelling support (e.g., swelling pm, swelling tube), an adhesive lined support, an adhesive lined separator, and combinations thereof.

[0078] In some embodiments, gravity activation includes insertion and activation of the post-wind support by gravity and / or filling of the internal diameter. In some embodiments, post-wind supports utilizing gravity activation include a material fill support(e.g., ball fill support (e.g., a material fill support insert)), an expanding foam support, reactive material supports (e.g., a two-part adhesive), and combinations thereof.

[0079] In some embodiments, friction activation includes applying friction from the post-wind support to a layer of the electrode assembly within the inner diameter (e.g., separator) to reduce the inner diameter and / or tighten the electrode assembly around the postwind support insert. In some embodiments, post-wand supports utilizing friction activation include a boring support (e.g., boring tube, boring pm), a low friction needle support, a diamond like coated support, and combinations thereof.

[0080] In some embodiments, temperature activation includes applying heat and / or cold temperatures to the post- wand support and / or inner diameter. In some embodiments, postwand supports utilizing temperature activation include a reforming support, a melting support, and combinations thereof.

[0081] In some embodiments, the post- winding support does not contact the cell when inserted and cycling of the cell creates contact between the inner diameter and the postwinding insert. Examples of a non-actuation mechanism are a loose tube support, a loose pin support and combinations thereof.

[0082] Table A, Table B and Table C list some post-winding support inserts along with various possible activation (e.g., actuation) mechanisms, materials, potentials and other characteristics.Radial Coil Support Insert

[0083] A radial coil support insert is a sheet of a material that is wound and may be inserted into the inner diameter before being activated. In some embodiments, the radial coil support insert can be a spring. In some embodiments, the radial coil support insert can be a radial spring (e.g., a mainspring, spiral torsion, or watch spring). In some embodiments, the radial coil support insert can include a height that is substantially larger than the radius of the radial coil support insert. In some embodiments, the radial coil support insert can be formed from a metal ribbon. Advantageously, in some embodiments, the radial coil support insert minimizes manufacturing and supply costs. In some embodiments, the radial coil support insert is wound and secured with an adhesive, installed into the inner diameter (e.g., through the e- fill port), and the electrolyte causes the adhesive to dissolve allowing the coil to spring open and achieve intimate contact with the inner diameter. In some embodiments, the radial coil support insert is secured mechanically (e.g., by an insertion device, such as a collar, a collet, a plunger, or combinations thereof) and activated once inserted into the inner diameter of a wound electrode assembly and the mechanical securing support (e.g., the insertion device) is removed.

[0084] In some embodiments, the radial coil support insert is secured by an adhesive. In some embodiments, the adhesive is applied to the radial coil support insert alone, by a tape (e.g., single sided tape, double sided tape), or combinations thereof. In some embodiments, the adhesive is selected to dissolve in the electrolyte. In some embodiments, the radial coil support insert includes an isolator (e.g., a bumper) located at one or more ends of the radial coil support insert.

[0085] FIGS. 3A-9 depict radial coil support inserts in unwound, wound, nonactivated, and activated configurations within and outside of the energy storage device, as well as insertion methods and insertion devices thereof.

[0086] FIG. 3A illustrates a detailed view of a portion of an energy storage device 300 including a wound electrode assembly 310 and a radial coil support insert 330 in anactivated configuration. The wound electrode assembly 310 includes an anode 312, a cathode 314, a separator, where the separator is disposed between the anode 312 and the cathode 314. The wound electrode assembly 310 is wound about a central axis to form an inner diameter surface 324 surrounding a cylindrical or an approximately cylindrical void. The anode 312 includes an anode start 322. The cathode 314 includes a cathode start 326. The radial coil support insert 330 includes a coil support start 334 and a coil support end 332. The radial coil support start 334 is positioned at an inner diameter of the radial coil support insert 330 and the radial coil support end 332 is positioned at an outer diameter of the radial coil support insert 330. The radial coil support insert 330 includes a radially coiled body having a plurality of concentric coils (e.g., layers) between radial coil support start 334 and the radial coil support end 332.

[0087] In some embodiments, the radial coil support start 334 is flat so that the core is not obstructed for electrolyte flow or ultrasonic weld probes. In some embodiments, the radial coil support start 334 includes a small flap which can be gripped onto.

[0088] Advantageously, the number of coils (e.g., layers) between the radial coil support start 334 and the radial coil support end 332 can be increased to increase the force supplied from the radial coil support insert 330 to the inner diameter of the wound electrode assembly 310. The number of coils between the radial coil support start 334 and the radial coil support end 332 can be decreased to decrease the force supplied from the radial coil support insert 330 to the inner diameter of the wound electrode assembly 310. In some embodiments, the radial coil support insert, in the non-activated configuration can include, include about, include at least, or include at least about 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20 or any range of values therebetween. In some embodiments, the radial coil support insert in the activated configuration can include, include about, include at least, or include at least about 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15 or any range of values therebetween. The thickness (i.e., the thickness of the material of one coil of the radial coil support insert) of the radial coil support insert can be increased to increase the force supplied from the radial coil support insert 330 to the inner diameter surface of the wound electrode assembly 310. The thickness of the radial coil support can be decreased to decrease the force supplied from the radial coil support insert 330 to the inner diameter surface of the wound electrode assembly 310. In some embodiments, the thickness of the material of the radial coil support is, is about,or is at most 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 or any range of values therebetween.

[0089] In some embodiments, the radial coil support has a buckling resistance (e.g. , stiffness) of, of about, or of at least about 0.001 GPa, 0.01 GPa, 0.1 GPa, 0.2 GPs, 0.3 GPa, 0.4 GPa, 0.5 GPa, 0.6 GPa, 0.7 GPa, 0.8 GPa, 0.9 GPa, 1 GPa, 1.1 GPa, 1.2 GPa, 1.3 GPa, 1.4 GPa, 1.5 GPa, 1.6 GPa, 1.7 GPa, 1.8 GPa, 1.9 GPa, 2 GPa, or any range of values therebetween. In some embodiments, the radial coil support has a buckling resistance (e.g., stiffness) of about 0.001 to 1.6 GPa. In some embodiments, an aluminum radial coil support has a buckling resistance of about 0.001 GPa to 0.1 GPa. In some embodiments, a spring steel radial coil support has a buckling resistance of about 0.1 GPa to 2 GPa.

[0090] In some embodiments, in the non-activated configuration the inner diameter of the radial coil support is, is about, or is at least about 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, or any range of values therebetween. In some embodiments, in the activated configuration the outer diameter of the radial coil support is, is about, or is at least about 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, 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, 7.1 mm, 7.2 mm, 7.3 mm, 7.4 mm, 7.5 mm, 7.6 mm, 7.7 mm, 7.8 mm, 7.9 mm, 8 mm or any range of values therebetween. In some embodiments, the radial coil support start includes an overbend edge that can be bent in an opposite direction from the direction of the coil.

[0091] In some embodiments, the wound electrode assembly is wound clockwise from the anode start outward. In some embodiments, the wound electrode assembly is wound counter-clockwise from the anode start outward. In some embodiments, the radial coil support insert is wound clockwise from the coil support start outward. In some embodiments, the radial coil support insert is wound counter-clockwise from the coil support start outward. In some embodiments, the wound electrode assembly is wound the same direction as the radial coil support insert. In some embodiments, the wound electrode assembly and radial coil support insert are wound in opposing directions.

[0092] In some embodiments, the radial coil support insert is clocked relative to the wound electrode assembly such that the anode start 322 is positioned adjacent to the coil support end 332. In some embodiments, the radial coil support insert is clocked relative to the wound electrode assembly such that the anode start 322 is positioned at an angle from the coil support end 332. In some embodiments, the angle between the anode start 322 and the coil support end 332 is or is about 1 degree, 5 degrees, 10 degrees, 15 degrees, 20 degrees, 25 degrees, 30 degrees, 35 degrees, 40 degrees, 45 degrees, 50 degrees, 55 degrees, 60 degrees, 65 degrees, 70 degrees, 75 degrees, 80 degrees, 85 degrees, 90 degrees, 95 degrees, 100 degrees, 105 degrees, 110 degrees, 115 degrees, 120 degrees, 125 degrees, 130 degrees, 135 degrees, 140 degrees, 145 degrees, 150 degrees, 155 degrees, 160 degrees, 165 degrees, 170 degrees, 175 degrees, 180 degrees, 185 degrees, 190 degrees, 195 degrees, 200 degrees, 205 degrees, 210 degrees, 215 degrees, 220 degrees, 225 degrees, 230 degrees, 235 degrees, 240 degrees, 245 degrees, 250 degrees, 255 degrees, 260 degrees, 265 degrees, 270 degrees, 275 degrees, 280 degrees, 285 degrees, 290 degrees, 295 degrees, 300 degrees, 305 degrees, 310 degrees, 315 degrees, 320 degrees, 325 degrees, 330 degrees, 335 degrees, 340 degrees, 345 degrees, 350 degrees, 355 degrees, 360 degrees, or any range of values therebetween.

[0093] FIG. 3B illustrates a radial coil support insert 330 transitioning from a nonactivated configuration radial coil support insert 330 A to an activated configuration radial coil support insert 330B relative to an inner diameter surface 324 of a wound electrode assembly. The non-activated configuration of the radial coil support insert 330A has clearance to the wound electrode assembly inner diameter surface 324. The activated configuration of the radial coil support insert 330B is in contact with the wound electrode assembly inner diameter surface 324.

[0094] FIGS. 4A illustrates a radial coil support insert 430 / X including an adhesive layer 436A. As illustrated, the adhesive layer 436A covers the outer diameter of the radial coil support insert 430 A. The adhesive layer 436A covers the lateral surface of the radial coil support insert 430A. In some embodiments, the adhesive layer can dissolve when in contact with electrolyte.

[0095] FIG. 4B illustrates a radial coil support insert 430B including an adhesive layer 436B. As illustrated, the adhesive layer 436A covers the radial coil support end. Theadhesive layer 436B covers a portion of the lateral surface of the radial coil support insert 43 OB.

[0096] FIG. 5 illustrates a radial coil support insert 530 prior to winding. The radial coil support insert 530 includes a radial coil support start 532 at a first end and a radial coil support end 534 at a second end. An adhesive layer 536 is positioned over the radial coil support end 534.

[0097] FIG. 6A illustrates a radial coil support insert 630 prior to winding. The radial coil support insert 630 includes a radial coil support start 632 at a first end and a radial coil support end 634 at a second end. An adhesive layer 636 is positioned over the radial coil support end 634. An isolator 638 is positioned over an edge between the radial coil support start 632 and the radial coil support end 634. FIG. 6B illustrates a cross-section of the radial coil support insert 630. As illustrated, the radial coil support insert 630 includes a laminate layer 640 and a metal layer 642. An upper edge of the laminate layer 640 is folded over itself to form a isolator 638.

[0098] FIG. 7A illustrates a radial coil support insert 730 prior to winding. The radial coil support insert 730 includes a radial coil support start 732 at a first end and a radial coil support end 734 at a second end. An adhesive layer 736 is positioned over the radial coil support end 734. The radial coil support insert 730 is laminated and includes a laminated edge 738. FIG. 7B illustrates a cross-section of the radial coil support insert 730. As illustrated, the radial coil support insert 730 includes a laminate layer 740, a second laminate layer 746 and a metal layer 742.

[0099] FIG. 8A illustrates a radial cross-section view' of an installation apparatus for installing a radial coil support insert 830 / X in a wound electrode assembly 810. The radial coil support insert 830A and wound electrode assembly 810 are aligned with a centerline 870 of the apparatus. The apparatus includes a collar 850 and a plunger 860. The collar 850 is a hollow cylinder having a chamfered edge 852 at a first end. A first end of the radial coil support insert 830A is positioned adjacent to the chamfered edge 852. The collar 850 is positioned interior to the inner diameter of the wound electrode assembly 810. A radial coil support insert 830 A in a non-activated configuration is positioned interior to the inner diameter of the collar 850. The plunger 860 is positioned interior to the inner diameter of the collar 850. The plunger 860 is positioned against a second end of the radial coil support insert 830A.

[0100] FIG. 8B illustrates a cross-section view of another embodiment of an installation apparatus for installing a radial coil support insert 830A in a wound electrode assembly 810 positioned in a can 802. The apparatus includes a collet holder 858 which engages with a collet 854. The collet 854 is positioned around the radial coil support insert 830 A to restrain the radial coil support insert 830 A in a non-activated configuration during installation. A push pin 862 extends through the collet 854 to push the radial coil support insert 830 A against a pm stopper 864. The pin stopper 864 fixes the depth of the radial coil support insert 830A relative to the wound electrode assembly 810. The push pin 862 can then be retracted and the collet 854 removed. Once the collet 854 the radial coil support insert 830 A is no longer constrained to the non-activated configuration.

[0101] In some embodiments, the installation apparatus and / or radial coil support insert may facilitate core reform and have geometry and structure designed in such a way that it moves a separator of the wound electrode assembly within the core area out of the way to make space for the installation apparatus and / or radial coil support insert. In some embodiments, the installation apparatus and / or radial coil support insert includes a sharp tip and / or a streamlined tip. In some embodiments, the installation apparatus includes an umbrella mechanism including a sharp tip which can be folded inward and outward. The sharp tip can advantageously assist in installing the support insert around the wound electrode assembly,

[0102] FIG. 8C illustrates a radial cross-section view of a radial coil support insert 830B in a core of a wound electrode assembly 810 after the installation apparatus is removed. The radial coil support insert 830B and wound electrode assembly 810 are aligned at the centerline 870. The activated radial coil support insert 830B is positioned interior to the inner diameter of the wound electrode assembly 810. The outer diameter of the radial coil support insert 830B is in contact with the inner diameter surface of the wound electrode assembly 810. Advantageously, in the activated configuration, the radial coil support insert 830B applies pressure on the inner diameter of the wound electrode assembly 810 to support the wound electrode assembly 810.

[0103] The plunger 860 can position the depth of the radial coil support insert 830A relative to the wound electrode assembly 810. Once the radial coil support insert 830A is activated to become an activated radial coil support insert 830B, the radial coil support insert 830B expands at the fixed depth set by the plunger 860. This advantageously fixes the positionof the activated radial coil support insert 83 OB in a floating position whereby the activated radial coil support insert 830B is not in electrical communication with the anode or the cathode and therefore is at a floating potential.

[0104] The radial coil support insert 830B advantageously has a hollow, substantially cylindrical shape that during cell runaway can survive peak temperatures while facilitating integrity at the central core and providing a gas egress path which can delay cell failure.

[0105] FIG. 9 illustrates an energy storage device 900 including a can 902, a wound electrode assembly 910 disposed interior to the can 901, a radial coil support insert 930 disposed interior to the wound electrode assembly 910, and a lid 908 positioned over the can 902.Die Forming Support Insert

[0106] A die forming support insert may be inserted into the inner diameter before being activated by expanding the diameter of the die forming support insert (e.g., plastic deformation) to achieve contact with the inner diameter. In some embodiments, a ball forming die (e.g., shown in FIGS. 11 A, 11B, 13A and 13B) and / or a progressive forming die (e.g., shown in FIG. 12) is inserted into the center of the die forming support insert to deform and expand the die forming support insert. In some embodiments, the die used to activate the die forming support insert is also used to seal the cell before and / or after electrolyte fill.

[0107] FIGS. 10A-13B depict die forming support inserts in non-activated and activated configurations within and outside of the energy storage device, as well as insertion methods and insertion devices thereof.Telescoping Support Insert

[0108] A telescoping support insert includes a relatively soft tube inserted into the inner diameter, and the soft tube is expanded and activated with the insertion of a relatively stiffer tube and / or pin into the center of the soft tube so that the soft tube is in contact with the inner diameter.

[0109] FIGS. 14A-14D depict telescoping support inserts in non-activated and activated configurations within and outside of the energy storage device, as well as activation methods, insertion methods and insertion devices thereof.Borins Support Insert

[0110] .A boring support insert is positioned within the inner diameter, and rotating the boring support insert causes circumferential friction with the inner diameter thereby causing activation and the inner diameter to cinch up against the boring support insert. In some embodiments, the boring support insert has a surface with increased roughness, grooves, tooth shaped feature, or combinations thereof. In some embodiments, the surface of the boring support insert includes a greater circumferential roughness relative to an axial roughness.

[0111] FIGS. 15A-16B depict boring support inserts in non-activated and activated configurations within and outside of the energy storage device, as w-ell as insertion methods and insertion devices thereof.Lock Spring, Support Insert

[0112] A lock spring support insert includes a compliant material (e.g., metal and / or polymer) that may be inserted into the inner diameter and activated by expansion (e.g,, via radial pressure), wherein the lock spring support insert includes a locking feature that prevents the lock spring support insert from collapsing after expanding.

[0113] FIGS. 17A-18B depict lock spring support inserts in non-activated and activated configurations within and outside of the energy storage device, as well as insertion methods and insertion devices thereof.Retaining Ring Support Insert

[0114] A retaining ring support insert includes a compliant material (e.g., metal and / or polymer that may be compressed and inserted into the inner diameter, and once released the retaining ring support insert activates and expands. In some embodiments, the retaining ring support insert has features to minimize step size and / or gaps in solution.

[0115] FIGS. 19-20B depict retaining ring support inserts in non-activated and activated configurations within and outside of the energy storage device, as w'ell as insertion methods and insertion devices thereof.Material Fill Support insert

[0116] A material fill support insert may be used to fill the inner diameter with a support material (polymer, foam, metal) before and / or after electrolyte filling (e.g., through the electrolyte fill port), wherein gravity' and / or density of the support material lead to the material curing while in intimate contact with the inner diameter. In some embodiments, the nonactivated material fill support insert includes a shape and / or viscosity selected to fill the inner diameter and / or avoid flowing past the inner diameter. In some embodiments, the material fill support insert is activated by curing the non-activated material (e.g., before and / or after swelling during and / or after formation cycling). In some embodiments, the activated material fill support insert improves thermal conductivity' within the inner diameter of the cell.

[0117] FIG. 21 depicts a material fill support insert within the energy storage device, as well as insertion methods and insertion devices thereof.Spiral Cable Support Insert

[0118] A spiral cable support insert includes a compliant support cut in a spiral such that when pulled axially the support radius decreases, and may be inserted into the inner diameter and released to activate and expand the spiral cable support insert to be in contact with inner diameter.

[0119] FIGS. 22-23B depict spiral cable support inserts in non-activated and activated configurations within and outside of the energy storage device, as well as insertion methods and insertion devices thereof.Swelling, Support Insert

[0120] A swelling support insert includes a support (e.g., swelling) material that may be inserted into the inner diameter and then activated and expanded when exposed to a liquid (e.g., electrolyte) to be in contact with inner diameter. FIG. 24 depicts swelling support inserts that is activated and swelling.Loose Tube or Pin Support Insert

[0121] A loose tube or pm support insert may be inserted into the inner diameter, and once the electrode assembly expands and swells through cycling the inner diameter is supported by the loose tube or pin support insert.

[0122] FIGS. 25-26B depicts a loose tube support insert within an electrode assembly, as well as insertion methods and insertion devices thereof.

[0123] FIG. 25 illustrates a detailed view of a portion of an energy storage device 2500 including a wound electrode assembly 2510 and a loose tube insert 2530 in an activated configuration. The wound electrode assembly 2510 includes an anode 2512, a cathode 2514, a separator, where the separator is disposed between the anode 2512 and the cathode 2514. The wound electrode assembly 2510 is wound about a central axis to form an inner diameter surface 2524 surrounding a cylindrical or an approximately cylindrical void. The loose tube insert 2530 is a hollow cylinder. In some embodiments, the hollow' cylinder shape advantageously improves electrolyte flow in the energy storage device 2500, There is clearance between the loose tube insert 2530 and the inner diameter surface 2524 of the wound electrode assembly 2510.

[0124] In some embodiments, the clearance between the loose tube insert and the inner diameter of the wound electrode assembly is about 0.5 mm. In some embodiments, the clearance between the loose tube insert and the inner diameter surface of the wound electrode assembly is at least 0.5 mm. In some embodiments, the clearance between the loose tube insert and the inner diameter surface of the wound electrode assembly 2510 is, is about, is at least, or is at least about 0 mm, 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, or any range of values therebetween. Advantageously, in some embodiments, reducing the clearance between the lease tube insert and the inner diameter surface of the wound electrode assembly reduces the radius of curvature of the inner diameter surface of the wound electrode assembly .

[0125] FIGS. 26A and 26B illustrate radial cross-sectional views of an energy storage device 2600 such that the energy storage device 2600 is revolved around a centerline 2670. FIG. 26A illustrates the energy storage device 2600 before the wound electrode assembly 2610A swells. FIG. 26B illustrates the energy storage device 2600 after the wound electrodeassembly 261 OB swells. The energy storage device 2600 includes a can 2602, a wound electrode assembly 2610A disposed in the can 2602, a loose tube insert 2630 disposed within an inner diameter surface of the wound electrode assembly 2610A, and a lid 2608 is positioned over an open end of the can 2602. The loose tube insert 2630 is installed in the can 2602 by passing the loose tube insert 2630 through an electrolyte fill opening in the lid 2608. As illustrated, the loose tube insert 2630 is positioned over an isolator 2620. The isolator 2620 can advantageously create a floating potential between the loose tube insert 2630 and the energy storage device 2600.

[0126] In some embodiments, a leading tip of the loose tube insert includes a chamfered outer edge. Advantageously, the chamfered outer edge can improve the ease of insertion of the loose tube insert.

[0127] In some embodiments, the loose tube insert includes an isolator on one or both ends. The isolators can be formed of an insulating material. The isolators can be stickers attached to the loose tube insert. In some embodiments, the isolator can act as a bumper. In some embodiments, the isolators can attach to one or both interior ends of the can. The isolators can advantageously isolate the loose tube insert from contacting the can.

[0128] In some embodiments, the loose tube insert can be formed from a polymer material. In some embodiments, the loose tube insert is formed from a material that swells when in contact with an electrolyte. In some embodiments, the loose tube insert is coated with and / or surrounded by a swell tape material that swells when in contact with an electrolyte. Advantageously, the swell material and / or swell tape can facilitate fixing the loose tube insert in a floating position such that the loose tube insert does not contact the can or lid such that electrical communication is formed with the anode or cathode.Lid Rivet Insert

[0129] FIG. 27 depicts a lid rivet support insert within an energy storage device 2700. The energy storage device 2700 including a wound electrode assembly 2710 and a lid rivet support insert 2730 in an activated configuration. The lid rivet support insert 2730 is riveted to a lid 2708 of the energy storage device 2700. Advantageously, the lid rivet support insert 2730 is mechanically coupled (e.g., thermally tied) to lid 2708 with low' thermal resistance. The lid rivet support insert 2730 can thermally connect the core of the woundelectrode assembly 2710 to the outside of the energy storage device 2700. The core can be difficult to cool and thermally connecting the core to the outside of the energy storage device 2700 can decrease the thermal resistance between the core of the wound electrode assembly 2710 and a heat sink.

[0130] This thermal and mechanical connection advantageously increases the thermal performance (e.g., efficiency) of the energy storage device 2700. The improved thermal operating temperature gradients of the energy storage device 2700 to both the side surface of the can 2702 of the energy storage device 2700 and the base of the energy storage device 2700 (e.g., improved efficiency increases heat flow out of the core).Electrode Film Materials and Electrode Films

[0131] An electrode film mixture and an electrode film may include electrode active materials (e.g., cathode active materials) and formed using materials described herein. The particles for forming the active layer or electrode film may be combined with a material to provide an electrode film mixture. In some embodiments, the active layer or electrode film may be formed from the electrode film mixture such that weight percentages of the components of the active layer or electrode film and weight percentages of the components of the electrode film mixture are substantially the same.

[0132] In some embodiments, the active material is a cathode active material. 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., LiMn0.oFe0.4PO4; “LMFP”), lithium nickel manganese cobalt oxide (i.e., LiNixMnyCoi-x-yO2; “NMC”), lithium nickel cobalt aluminum oxide (i.e., LiNixCoyAlzO2; “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, the cathode active material is an iron phosphate-based active material. In some embodiments, iron phosphate- based active materials include LiFePO* (i.e., “lithium iron phosphate” and “LFP”) and LiMni-xFexPO4 (i.e., “lithium manganese iron phosphate” and“LMFP”) (e.g., LiMno.6Feo.4PO4 or LiMno sFeo.jPCh). In some embodiments, the iron phosphate-based active material includes LFP. In some embodiments, the iron phosphate- based active material includes an LMFP. In some embodiments, the iron phosphate-based active material includes an LFP and / or an LMFP.

[0133] In some embodiments, the active material is an anode active material. 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,

[0134] In some embodiments, the electrode film mixture and / or electrode film comprises the active material in an amount of, of about, of at least, or at least about, 70 wt.%, 75 wt.%, 80 wt.%, 85 wt.%, 86 wt.%, 87 wt.%, 88 wt.%, 89 wt.%, 90 wt.%, 91 wt.%, 92 wt.%, 93 wt.%, 94 wt.%, 95 wt.%, 96 wt.%, 97 wt.%, 98 wt.%, 98.5 wt.%, 99 wt.%, 99.5 wt.%, 99,8 wt.% or 99.9 wt.%, or any range of values therebetween.

[0135] In some embodiments, the electrode film mixture and / or electrode film comprises a carbon material configured to reversibly intercalate lithium ions. 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, graphenecontaining 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. In some embodiments, the electrode comprises the carbon material in a total amount of, of about, of at most, or at most about, 20 wt.%, 15 wt%, 10 wi.%, 9 wt.%, 8 wt.%, 7 wt.%, 6 wt%, 5 wt.%, 4 wt.%, 3 wt.%, 2 wl.%, 1 wt.%, or any range of values therebetween.

[0136] In some embodiments, an electrode film mixture and / or an electrode film includes a conductive additive. In some embodiments, the conductive additive may comprise a conductive carbon additive, such as a carbon black. In some embodiments, the conductive additive is carbon black. In some embodiments, the conductive additive may comprise a conductive carbon additive. In some embodiments, the conductive carbon additive comprises carbon black, carbon nanotubes. In some embodiments, the conductive additive is selected from a conductive carbon, a carbon nanotube, and combinations thereof. In some embodiments, the carbon nanotube is selected from a single-walled carbon nanotube (SWCNT), multi-walled carbon nanotube (MWCNT), a few-walled carbon nanotube (FWCNT), and combinations thereof. 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.%, 0.09 wt.%, 0.08 wt.%, 0.07 wt.%, 0.06 wt.%, 0.05 wt.%, 0.04 wt.%, 0.03 wt.%, 0.02 wt.%, 0.01 wt.% of the electrode film, or any range of values therebetween.

[0137] In some embodiments, the electrode film mixture and / or the electrode film includes a binder or binder material (e.g., binder, additional binder). In some embodiments, binders can include polytetrafluoroethylene (PTFE), a polyolefin, polyalkylenes, polyethers, styrene-butadiene, co-polymers of polysiloxanes and polysiloxane, branched polyethers, polyvinylethers, a carboxymethylcellulose (CMC), co-polymers thereof, and / or combinations thereof. In some embodiments, the polyolefin can include polyethylene (PE), polypropylene (PP), polyvinylidene fluoride (PVDF), co-polymers thereof, and / or combinations thereof. For example, the binder can include polyvinylene chloride, poly(phenylene oxide) (PPO), polyethylene-block-poly(ethylene glycol), polyethylene oxide) (PEO), poly(phenylene oxide) (PPO), polyethylene-block-poly(ethylene glycol), polydimethylsiloxane (PDMS), polydimethylsiloxane-coalkylmethylsiloxane, polyalkylenes, polyethers, styrene-butadiene, styrene-butadiene rubber (SBR), co-polymers of polysiloxanes and polysiloxane, branched polyethers, polyvinylethers, co-polymers thereof, and / or combinations thereof. In some embodiments, the binder may include a thermoplastic. In some embodiments, the binder comprises a fibrillizable and / or fibrillized polymer. In certain embodiments, the binder comprises, consists essentially, or consists of a single fibrillizable and / or fibrillized binder, such as PTFE. In some embodiments, the electrode film includes, includes about, includes atmost, or includes at most about, 0.2 wt.%, 0.4 wt.%, 0.6 wt.%, 0.8 wt.%, 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.

[0138] 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.

[0139] 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, or combinations of the foregoing. Insome 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 um, 100 μm, 50 μm , 40 μm , 30 μm , 20 μm, 15 μm, 10 μm , 5 μm, or any range of values therebetween.Electrodes and Energy Storage Devices

[0140] An energy storage system or device includes a positive electrode (i.e., cathode), a negative electrode (i.e., anode), a separator disposed therebetween, and an electrolyte positioned within a housing. Each electrode includes an electrode film disposed over a current collector. The electrode includes an electrode film disposed over a current collector. In some embodiments, the current collector is a foil. In some embodiments, the current collector is aluminum foil, a copper foil, or combinations thereof In some embodiments, a current collector can include a metallic material, such as a material comprising aluminum, nickel, copper, or 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 gm, 50 gm, 40 pm, 30 gm, 20 gm, 15 pm, 10 gm, 5 gm, or any range of values therebetween. In some embodiments, an active layer is disposed on each side of the current collector.

[0141] 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 bottomelectrode film. In some embodiments, each of the two electrode films can have any suitable shape, size and thickness.

[0142] 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.

[0143] An electrode assembly includes a cathode, an anode, and a separator positioned between the anode and cathode. In some embodiments, the electrode assembly is a wound electrode (i.e., rolled electrode) assembly (e.g., a “jellyroll”). 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.

[0144] The normalized circularity may be used to determine and / or correlate to a relatively weak core spot (e.g., a spot that may cause electrode buckling) in the wound electrode assembly. Normalized circularity for a nonideal spiral is defined as the minimum ratio between the nonideal (real) geometry versus ideal geometry on a point-by-point basis according to the equation below.

[0145] The nonideal (real) spiral geometry is given by measured Cartesian and polar coordinatesand the ideal spiral geometry’ is derived from an Archimedean spiral according to The geometry of a spiral (ideal or nonideal) can becharacterized by curvature (X), such as the polar curvature parameterization below.

[0146] In some embodiments, the electrode assembly comprises a normalized circularity value of, of about, of at least, or of at least about, 0.7, 0.705, 0.71, 0.715, 0.72,0.725, 0.73, 0.735, 0.74, 0.745, 0.75, 0.76, 0.77, 0.78, 0.79, 0.8, 0.805, 0.81, 0.815, 0.82, 0.825, 0.83, 0.835, 0.84, 0.845, 0.85, 0.86, 0.87, 0.88, 0.89, 0.9, 0.91, 0.92, 0.93, 0.94, 0.95, 0.96, 0.97, 0.98, 0.99, 1, 1.05, 1.1, 1.15, 1.2 or any range of values therebetween.

[0147] The electrode (e.g., cathode, anode) 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 batery. 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) which reduce greenhouse gas emissions.

[0148] In some embodiments, the energy storage device is charged with a suitable electrolyte (e.g., 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 salt includes an anion that is redox stable. In some embodiments, the anion can be monovalent. In some embodiments, the salt is a lithium salt. In some embodiments, a lithium salt can be selected from lithium hexafluorophosphatelithium bis(trifluoromethanesulfonyl)imide lithium tetrafluoroborate lithiumperchlorate lithium bis(trifluoromethansulfonyl)imide , lithiumtrifluoromethansulfonate lithium bis(oxalato)borate lithiumbis(fluorosulfonyl)imidelithium difluoro(oxalato)borate(L1C2BF2O4), lithium difluorophosphate (LiDFP), lithium bis(oxalate)borate (LiBOB), lithium difluoro(bisoxalato)phosphate (LiDFOP), and combinations thereof. In some embodiments, the electrolyte can include a quaternary ammonium 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. In some embodiments, salts are utilized as additives in the electrolyte system, and can be used at individual or total 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.

[0149] 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 liquid co-solvent can include one or more functional groups selected from dioxathiolane (e.g., l,3,2-dioxathiolane-2,2-dioxide (re., “DTD”)), carbonates, ethers and / or esters. In some embodiments, the liquid co-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), 1,3-propene sultone (PRS), and combinations thereof. In some embodiments, the liquid co-solvent can comprise an ester. In some embodiments, the ester is selected from methyl acetate (MA), methyl propionate (MP), ethyl acetate (EA), methyl butyrate (MB), and combinations thereof. In some embodiments, the liquid co-solvent cancomprise an acetate. In some embodiments, the acetate is selected from methyl acetate (MA), ethyl acetate (EA), and combinations thereof. In some embodiments, the liquid co-solvent can comprise a nitrile (e.g., acetonitrile (“AN”)). In some embodiments, the liquid co-solvent may include EC, PC, VEC, VC, EEC, DMC, DEC, EMC, MA, MP, EA, MB, DID, PRS, acetonitrile, and combinations thereof. In some embodiments, the liquid co-solvent may include EC, DMC, DEC, EMC, MA, and combinations thereof. In some embodiments, the liquid co-solvent may include EC, DMC, EMC, and combinations thereof. In some embodiments, the liquid co-solvent may include MA.

[0150] In some embodiments, one or more solvents can be used at a concentration of, of about, of at least, or at least about, 15 wt.%, 20 wt.%, 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.%.

[0151] 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 film is easier to identify and therefore improves the ability to form a counter electrode (e.g., anode electrode) with an overhang.

[0152] While certain embodiments have been described, these embodiments have been presented by way of example only, and are not intended to limit the scope of the disclosure. Indeed, the novel methods and systems described herein may be embodied in avariety of other forms. Furthermore, various omissions, substitutions and changes in the systems and methods described herein may be made without departing from the spirit of the disclosure. The accompanying claims and their equivalents are intended to cover such forms or modifications as would fall within the scope and spirit of the disclosure.

[0153] Features, materials, characteristics, or groups described in conjunction with a particular aspect, embodiment, or example are to be understood to be applicable to any other aspect, embodiment or example described in this section or elsewhere in tins specification unless incompatible therewith. All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and / or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and / or steps are mutually exclusive. The protection is not restricted to the details of any foregoing embodiments. The protection extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.

[0154] Furthermore, certain features that are described in this disclosure in the context of separate implementations can also be implemented in combination in a single implementation. Conversely, various features that are described in the context of a single implementation can also be implemented in multiple implementations separately or in any suitable subcombination. Moreover, although features may be described above as acting in certain combinations, one or more features from a claimed combination can, in some cases, be excised from the combination, and the combination may be claimed as a subcombination or variation of a subcombmation.

[0155] Moreover, while operations may be depicted in the drawings or described in the specification in a particular order, such operations need not be performed in the particular order shown or in sequential order, or that all operations be performed, to achieve desirable results. Other operations that are not depicted or described can be incorporated in the example methods and processes. For example, one or more additional operations can be performed before, after, simultaneously, or between any of the described operations. Further, the operations may be rearranged or reordered in other implementations. Those skilled in the art will appreciate that in some embodiments, the actual steps taken in the processes illustratedand / or disclosed may differ from those shown in the figures. Depending on the embodiment, certain of the steps described above may be removed, others may be added. Furthermore, the features and attributes of the specific embodiments disclosed above may be combined in different ways to form additional embodiments, all of which fall within the scope of the present disclosure. Also, the separation of various system components in the implementations described above should not be understood as requiring such separation in all implementations, and it should be understood that the described components and systems can generally be integrated together in a single product or packaged into multiple products. For example, any of the components for an energy storage system described herein can be provided separately, or integrated together (e.g., packaged together, or attached together) to form an energy storage system.

[0156] For purposes of this disclosure, certain aspects, advantages, and novel features are described herein. 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.

[0157] Conditional language, such as “can,” “could,” “might,” or “may,” unless specifically stated otherwise, or otherwise understood within the context as used, is generally intended to convey that certain embodiments include, while other embodiments do not include, certain features, elements, and / or steps. Thus, such conditional language is not generally intended to imply that features, elements, and / or steps are in any way required for one or more embodiments or that one or more embodiments necessarily include logic for deciding, with or without user input or prompting, whether these features, elements, and / or steps are included or are to be performed in any particular embodiment.

[0158] Conjunctive language such as the phrase “at least one of X, Y, and Z,” unless specifically stated otherwise, is otherwise understood with the context as used in general to convey that an item, term, etc. may be either X, Y, or Z. Thus, such conjunctive language is not generally intended to imply that certain embodiments require the presence of at least one of X, at least one of Y, and at least one of Z.

[0159] Language of degree used herein, such as the terms “approximately,” “about,” “generally,” and “substantially” as used herein represent a value, amount, or characteristic close to the stated value, amount, or characteristic that still performs a desired function or achieves a desired result. For example, the terms “approximately,” “about,” “generally,” and “substantially” may refer to an amount that is within less than 10% of, within less than 5% of, within less than 1% of, within less than 0.1% of, and within less than 0.01% of the stated amount, depending on the desired function or desired result.

[0160] The scope of the present disclosure is not intended to be limited by the specific disclosures of preferred embodiments in this section or elsewhere in this specification, and may be defined by claims as presented in this section or elsewhere in this specification or as presented in the future. The language of the claims is 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.

[0161] The headings provided herein, if any, are for convenience only and do not necessarily affect the scope or meaning of the devices and methods disclosed herein.

Claims

WHAT IS CLAIMED IS:

1. An energy storage device comprising: a can; a wound electrode assembly comprising an anode, a cathode and a separator, wherein the separator is disposed between the anode and the cathode, and wherein the wound electrode assembly is wound about a central axis to form an inner diameter surface surrounding a cylindrical void, the wound electrode assembly disposed interior to the can; the post-winding support insert comprising a radial spring comprising a coiled body having a plurality of layers, a start positioned at an inner diameter surface of the radially coiled body and an end positioned at an outer diameter of the radially coiled body; wherein the post-winding support insert is positioned against the inner diameter surface of the wound electrode assembly; and a lid positioned over the can.

2. The energy storage device of claim 1, wherein the wound electrode assembly is wound clockwise from an anode start outward and the post-winding support insert is wound clockwise from the anode start outward.

3. The energy storage device of claim 1 , wherein the wound electrode assembly is wound clockwise from an anode start outward and the post-winding support insert is wound counter-clockwise from the anode start outward.

4. The energy storage device of claim 1 , wherein the post-winding support insert comprises a material selected from stainless steel, aluminum, and combinations thereof.

5. The energy storage device of claim 4, wherein the stainless steel is selected from a group consisting of 301 SS, 304 SS, 316 SS, and combinations thereof.

6. The energy storage device of claim 2, wherein the post-winding support insert is floating relative to the can.

7. An energy storage device comprising: a can; a w'ound electrode assembly comprising an anode, a cathode and a separator, wherein the separator is disposed between the anode and the cathode, and wherein thewound electrode assembly is wound about a central axis to form an inner diameter surface surrounding a cylindrical void, the wound electrode assembly disposed interior to the can; and a post-winding support insert positioned interior to the inner diameter surface of the wound electrode assembly, wherein the post-winding support insert comprises an isolator positioned against a first end of the post-winding support insert.

8. The energy storage device of claim 7, wherein the post- winding support insert comprises a tube.

9. The energy storage device of claim 7, wherein the post-winding support insert comprises a swell material.

10. The energy storage device of claim 7, further comprising a second isolator positioned against a second end of the post- winding support insert.

11. The energy storage device of claim 7, wherein the post-winding support insert comprises a swell tape material positioned around an outer diameter of the tube.

12. The energy storage device of claim 11, wherein the swell tape material is configured to swell when in contact with an electrolyte.

13. The energy storage device of claim 7, wherein an outer diameter of the postwinding support insert is within 0.5 mm or less of the inner diameter surface of the wound electrode assembly.

14. The energy storage device of claim 7, wherein the post-winding support insert is coupled with low thermal resistance to the can.

15. An energy storage device comprising: a can; a wound electrode assembly comprising an anode, a cathode and a separator, wherein the separator is disposed between the anode and the cathode, and wherein the wound electrode assembly is wound about a central axis to form an inner diameter surface surrounding a cylindrical void, the wound electrode assembly disposed interior to the can; and a post-winding support insert positioned interior to the inner diameter surface of the wound electrode assembly, wherein the post-winding support insert is coupled with low thermal resistance to the can.

16. The energy storage device of claim 15, further comprising a lid, wherein the lid is connected to the post-winding support insert.

17. A method of supporting a center of a wound electrode assembly, comprising: providing the wound electrode assembly comprising an anode, a cathode and a separator, wherein the separator is disposed between the anode and the cathode, and wherein the wound electrode assembly is wound about a central axis to form an inner diameter surface surrounding a cylindrical void; inserting a non-actuated support insert within the cylindrical void; and activating the non-actuated support insert to form an actuated support insert substantially in contact with the inner diameter surface.

18. The method of claim 17, wherein the non-actuated support insert comprises a radial spring comprising a coiled body having a plurality of layers, a start positioned at an inner diameter surface of the radially coiled body and an end positioned at an outer diameter of the radially coiled body.

19. The method of claim 17, further comprising inserting the wound electrode assembly within a housing to form an energy storage device; and wherein activating the non-actuated support insert to form the actuated support insert substantially in contact with the inner diameter surface comprises cycling the energy storage device such that the wound electrode assembly swells.

20. The method of claim 17, wherein inserting the non-actuated support insert within the cylindrical void comprises: positioning the non-actuated support insert in a collet of an installation apparatus comprising a collet holder engaged with the collet, and a push pin which extends through the collet; and pushing the non-actuated support insert via the push pm against a pm stopper.

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