Enclosure packaging for electrochemical cell assemblies

Abstract

The present inventions relate to methods, devices, systems, apparatuses, controllers, software, and designs associated with packaging of at least one cell assembly in a space efficient manner, while the cell assembly is in the packaging. The space optimization comprises a folding scheme. The packaging of the cell assembly in the enclosure may include heat and / or pressure application onto the packaging, while the cell assembly is in the packaging, e.g., enclosure such as a pouch.

Description

Attorney Docket No. ENX-0159.WOENCLOSURE PACKAGING FOR ELECTROCHEMICAL CELL ASSEMBLIESPRIORITY APPLICATIONS

[0001] This application claims priority to U.S. Provisional Patent Application No. 63 / 734,000, filed on December 13, 2024, which is incorporated herein by reference in its entirety.BACKGROUND

[0002] The present invention relates to methods and structures such as electrode assemblies for use in energy manipulation (e.g., storage and / or release) devices such as batteries, to energy manipulation devices employing such structures, and to methods for manufacturing such structures and energy manipulation devices. In various examples, the present invention relates to the formation of secondary batteries, and in particular to the methods for manufacturing safer secondary batteries with improved energy densities.

[0003] Batteries such as lithium-based secondary batteries, are a type of energy manipulation (e.g., storage) device (also referred to herein as “the device’’ or “device’’) having electrochemical cells in which carrier ions, such as lithium, sodium, potassium, calcium, or magnesium ions, travel between a cathode structure and an anode structure through an electrolyte within each electrochemical cell (e.g., voltaic cell) abbreviated herein as “cell.” The anode structure and cathode structure in the cell are separated by a gap. The cell may include a separator structure. The separator structure may be incorporated in the battery cell during assembly of the battery and during battery operation. Anode and cathode current collectors of the respective anode and cathode, pool electric current from the respective active electrochemical electrodes and enable transfer (e.g., flow) of the current to the environment outside the battery. The cathode and anode structures may include cathodically active material layers and anodically active material layers, respectively. The cathodically active material layers may comprise a cathodically active material selected from transition metal oxides, transition metal sulfides, transition metal nitrides, lithium-transition metal oxides, lithium- transition metal sulfides, and lithium-transition metal nitrides. Suitable cathodically active materials include LiCoCh, LiNio sMm .5O4, Li(NixCoyAlz)02, LiFePCU, Li2MnC>4, and V2O5. Suitable anodically active material layers may comprise anodically active silicon, tin, aluminum, carbon, an oxide, a nitride, or an alloy thereof.

[0004] There are a number of shortcomings related to such energy manipulation devices and / or the process of making these devices. The interior assembly of lithium-ion secondary batteries are commonly enclosed within a pouch, which is sealed around a perimeter. The interior cell assembly may be at least one unit cell, or multiple unit cells electrically coupled in parallel with one another. The unit cells may be stacked in a direction parallel to a particular face of the secondary battery. Each unit cell may additionally comprise an insulator along an edge of the unit cell. This insulator may comprise a ceramic material. In some implementations,Attorney Docket No. ENX-0159.WO the sealing of the pouch around the perimeter is done via heat and / or pressure sealing. The sealing of the pouch creates one or more “flaps” around the perimeter. The pouch material can be a multi-layer film that comprises a metallic layer between two polymer layers. The metallic layer may act as a (e.g., diffusion) barrier to reactive species present in the ambient atmosphere external to the battery casing (e.g., enclosure such as a pouch). While this application refers to a casing as a pouch, the disclosure herein may refer to an enclosure different from a pouch. A pouch material can comprise an aluminum laminated film, which is an aluminum metallic layer laminated between two organic (e.g., polymeric) layers, such as polyphthalamide, polyamide, polypropylene, any plurality of types thereof, or any combination thereof. The organic layers may be carbon based and / or silicon based. During the lifetime of the battery, the enclosure may be damaged, e.g., deformed, ruptured, and / or cracked. Processing operations (e.g., final processing operations) of the enclosure may require its sealing followed by trimming any excess material. The trimming may cause puncturing of the barrier layer, and exposure of the enclosure interior to reactive species in the ambient environment external to the enclosure (e.g., oxygen, water, etc.). The reactive nature of the exposed metallic layer with such reactive agents may lead to degradation reactions that can with adverse effects. The adverse effects can to the energy manipulation device, to its user, to a facility in which the device is disposed, or any combination thereof. The adverse effects may be to the structural integrity and / or the electrochemical performance of the cell energy manipulation device, e.g., of the battery. The adverse effects may include corrosion, short circuitry, deposition of reduced form of charge carriers (e.g., dendrite formation), reduced battery performance, thermal runaway reactions, increased impedance, or any combination thereof. The inventions herein aims to prolong the lifespan of the secondary battery at least in part by sealing the components of the battery in an enclosure to isolate them from the reactive species, while minimizing a footprint of the enclosure to maximize the energy density of the device, e.g., by providing a packaging comprising a folding geometry of extended edges (e.g., extension) of the seal of the enclosure. The enclosure is configured to provide an insulating barrier protecting the material layers of the enclosure, and its interior, from outside forces.

[0005] Batteries such as secondary batteries used commercially, must undergo many tests to ensure that they are safe for the consumer. The many tests may comprise standard testing, e.g., jurisdictional and / or industrial testing. For example, a secondary battery may undergo a drop test where the secondary battery is dropped multiple times, e.g., at least about 100 drops, or 200 drops. If a (e.g., secondary) battery fails during a drop test, then the battery’s design may be deemed unsafe for consumers. Sometimes, a secondary battery has a stacked electrode design, e.g., and one or more grommets. The one or more grommets may keep the pouch of the secondary battery sealed to hinder (e.g., prevent) leaking of a fluid through the enclosure, the fluid (e.g., liquid) may comprise as an electrolyte mixture. In some embodiments,Attorney Docket No. ENX-0159.WO the (e.g., secondary) battery with a stacked electrode design (e.g., and one or more grommets) fails the drop test. Accordingly, there exists a need for improved (e.g., secondary) battery design and manufacturing to create a safer (e.g., secondary) battery that can pass the standardized testing such as the one or more drop tests.TECHNICAL FIELD OF INVENTION

[0006] The present disclosure relates enclosing electrochemical cell assemblies in an enclosure, and the compactization of the enclosure to increases its energy density, particularly the present disclosure relates to packaging the electrochemical cell assemblies in a packaging space efficient manner that will increase the safety parameters of the manufactured device.SUMMARY

[0007] In some aspects, the present disclosure resolves one or more of the aforementioned hardships and / or shortcomings. In some embodiments, the present disclosure provides solutions to curtail the aforementioned hardships and / or shortcomings. The solutions include method(s), device(s), apparatus(es), system(s), and / or design(s). In some aspects, the present inventions relate to method(s), device(s), apparatus(es), system(s), and design(s), utilized for a battery comprising cell(s). Methods, apparatuses, devices, program instructions, and structures, are disclosed herein to increase the energy density of an energy manipulation device (e.g., battery) by reducing its overall footprint. The reduction in the footprint may aid in increasing the robustness, resilience, and performance during its prescribed use, e.g., and in standardized testing such as disclosed herein.

[0008] In some aspects, techniques are disclosed herein for manufacturing an energy manipulation device such as a secondary battery, with a folded terrace, the terrace including at least one grommet and / or terminal tab of the cell assembly. For example, a secondary battery may comprise stacked electrodes separated from counter-electrodes by separators. The (e.g., secondary) battery may be positioned within a central body of the enclosure (e.g., the pouch). The enclosure may have an extension surrounding the central body. The extension may comprise a plurality of flaps. The flaps may be folded in a direction such that each of the flaps contacts a respective side of the central body. At least one controller (e.g., comprising a protection circuit module (PCM)), may be coupled with the enclosure, e.g., contacting one of its sides and / or faces. Each of the electrode and counter-electrode of the cell assembly, may be operatively coupled with an electrode terminal tab and a counter-electrode terminal tab, respectively, each of the terminal tabs extending from an interior of the enclosure to an exterior of the enclosure. Each of the terminal tabs may be coupled with the seal of the enclosure at least in part using respective grommets. One or more of the terminal tabs may be welded to welding pads of the PCM externally to the enclosure. A flap in which a terminal tab portion is disposed, may be referred to as a terrace. In some embodiments, the terrace flap is folded to create a folded terrace that is folded to (directly or indirectly) contact a side of the enclosure.Attorney Docket No. ENX-0159.WOThe folded terrace structure may reduce a footprint of the energy manipulation device (e.g., battery) and thus increase its energy density. In some embodiments, the folded terrace reinforces the sealing area, e.g., resulting in a safer secondary battery that can exhibit a greater endurance to the standardized testing, e.g., enduring additional drops and / or withstand internal fluctuations of pressure. In some embodiments, the energy manipulation device with the folded terrace has an improved energy density compared to a secondary battery having a non-folded terrace. The disclosed techniques for manufacturing the energy manipulation device with folded terrace(s) may be compatible with the manufacturing of wet-electrolyte (e.g., secondary) batteries and / or solid-state batteries.

[0009] In some aspects, techniques are disclosed herein for manufacturing a secondary battery with a folded terrace. For example, a secondary battery may comprise stacked electrodes and separators. The secondary battery may be positioned within a pouch defined by a battery enclosure. The enclosure may comprise a plurality of flaps. The plurality of flaps may be folded over or under a protection circuit module (PCM). Further, one or more cell tabs may be welded to welding pads of the PCM. In some embodiments, the flaps are folded to create a folded terrace. In some embodiments, the folded terrace reinforces the sealing area resulting in a safer secondary battery that can endure additional drops and withstand internal fluctuations of pressure. In some embodiments, the secondary battery with the folded terrace has an improved energy density compared to a secondary battery without a folded terrace. The disclosed techniques for manufacturing a secondary battery with a folded terrace may be compatible with the manufacturing of wet-electrolyte secondary batteries and / or solid-state batteries.

[0010] In another aspect, a secondary battery comprises: an electrode assembly, wherein the electrode assembly comprises a plurality of unit cells stacked in a stacking direction, each of the unit cells comprising an anode structure, a separator structure, and a cathode structure; a battery enclosure comprising a plurality of flaps and a terrace fold, wherein: the electrode assembly is housed within the battery enclosure; and at least two flaps of the plurality of flaps are folded to make the terrace fold; a protection circuit module (PCM) attached to the terrace fold, wherein the PCM comprises one or more welding pads; and one or more cell tabs welded to the one or more welding pads.

[0011] In another aspect, a secondary battery comprises: an electrode assembly, wherein the electrode assembly comprises a plurality of unit cells stacked in a stacking direction, each of the unit cells comprising an anode structure, a separator structure, and a cathode structure; and a battery enclosure comprising a plurality of flaps and a terrace fold, wherein: the electrode assembly is housed within the battery enclosure; and at least two flaps of the plurality of flaps are folded to make the terrace fold.Attorney Docket No. ENX-0159.WO

[0012] In another aspect, a method comprises: applying a first adhesive to a first face of a battery enclosure, wherein: the battery enclosure comprises a plurality of flaps; the battery enclosure houses an electrode assembly; and a first cell tab (e.g., first terminal tab) and a second cell tab (e.g., second terminal tab) extend from the electrode assembly; folding the first cell tab and the second cell tab in a first direction so that a first portion of the first cell tab and a first portion of the second cell tab contacts the first adhesive; folding a first flap of the plurality of flaps in a second direction, wherein: the second direction is perpendicular to the first direction; and the first flap is folded after the first cell tab and the second cell tab are folded in the first direction; folding a second flap of the plurality of flaps in a third direction, wherein: the third direction is perpendicular to the first direction; the third direction is opposite the second direction; and the second flap is folded after the first cell tab and the second cell tab are folded in the first direction; folding a portion of the first cell tab so that an end of the first cell tab extends away from the electrode assembly; and folding a portion of the second cell tab so that an end of the second cell tab extends away from the electrode assembly e.g., and from the central body housing the electrode assembly. In some embodiments, folding the portion of the first cell tab so that the end of the first cell tab extends away from the electrode assembly comprises folding the portion of the first cell tab approximately 90 degrees. In some embodiments, folding the portion of the second cell tab so that the end of the second cell tab extends away from the electrode assembly comprises folding the portion of the second cell tab approximately 90 degrees. In some embodiments, the method further comprises applying a first material to cover the first cell tab and the second cell tab. In some embodiments, the method further comprises welding the first cell tab to a first welding pad of a protection circuitry module (PCM). In some embodiments, the PCM is accommodated within a terrace area (e.g., flap comprising at least one terminal tab) of the electrode assembly. In some embodiments, the first adhesive is double sided foam tape, hot melt, and / or curing. The curing may comprise electromagnetic curing, chemical curing, or any combination thereof such as disclosed herein.

[0013] In another aspect, a method comprises: applying a first adhesive to a first face of a battery enclosure, wherein: the battery enclosure comprises a plurality of flaps; the battery enclosure houses an electrode assembly; and a first cell tab (e.g., first terminal tab) and a second cell tab (e.g., second terminal tab) extend from the electrode assembly; folding a first flap of the plurality of flaps in a first direction; folding a second flap of the plurality of flaps in a second direction, wherein the second direction is opposite the first direction; folding the first cell tab and the second cell tab in a third direction so that a first portion of the first cell tab and a first portion of the second cell tab contacts the first adhesive wherein; the third direction is perpendicular to the first direction and the second direction; and the first cell tab and the second cell tab are folded in the third direction after the first flap is folded in the first direction and the second flap is folded in the second direction; folding a portion of the first cell tab so that an endAttorney Docket No. ENX-0159.WO of the first cell tab extends away from the electrode assembly; and folding a portion of the second cell tab so that an end of the second cell tab extends away from the electrode assembly, e.g., and from the central body housing the electrode assembly. In some embodiments, folding the portion of the first cell tab so that the end of the first cell tab extends away from the electrode assembly comprises folding the portion of the first cell tab approximately 90 degrees. In some embodiments, folding the portion of the second cell tab so that the end of the second cell tab extends away from the electrode assembly comprises folding the portion of the second cell tab approximately 90 degrees. In some embodiments, the method further comprises applying a first material to cover the first cell tab and the second cell tab. In some embodiments, the method further comprises welding the first cell tab to a first welding pad of a protection circuitry module (PCM). In some embodiments, the PCM is accommodated within a terrace area (e.g., flap comprising at least one terminal tab) of the electrode assembly. In some embodiments, the first adhesive is double sided foam tape, hot melt, and / or curing.

[0014] In another aspect, a device for energy manipulation, the device comprises: a cell assembly comprising an electrode separated from a counter-electrode by a gap, the electrode coupled with an electrode terminal tab, the counter-electrode coupled with a counter-electrode terminal tab; and an enclosure comprising (a) a central body having a height along a height direction, the central body being configured to house the cell assembly, and (b) an extension extending from a periphery of the central body, the extension comprising flaps folded respectively along fold lines having a vectorial component along the height direction, the flaps being folded towards respective sides of the central body, the flaps being attached with the central body, the flaps comprising a first flap, a third flap, and a fourth flap opposing the third flap, the first flap being coupled (a) with the third flap by a first fold and (b) with the fourth flap by a second fold, the extension comprising a seal configured to hermetically seal the cell assembly in the enclosure, the electrode terminal tab and the counter-electrode terminal tab extending from the cell assembly through the extension to an external environment to the enclosure, the first flap comprising one or more of (i) the electrode terminal tab and (ii) the counter-electrode terminal tab. In some embodiments, the first fold and the second fold are attached with the first flap such that the first fold and the second fold face each other. In some embodiments, the fold lines are disposed in a plane. In some embodiments, the fold lines are disposed along a circumference of a back side of the central body opposing a front side of the central body, the back side and the front side being disposed along the height direction. In some embodiments, the back side is disposed in a plane normal to the height direction and / or the front side is disposed in a plane normal to the height direction. In some embodiments, the enclosure comprises a first portion adhered to a second portion. In some embodiments, the first portion comprises the front side and the second portion comprises the back side. In some embodiments, the enclosure comprises a cavity portion sealed with a lid portion. In someAttorney Docket No. ENX-0159.WO embodiments, the cavity portion comprises the front side and the lid portion comprises the back side. In some embodiments, the cavity portion assumes a cavity shape configured to accommodate a volume of the cell assembly. In some embodiments, the lid portion is planar and closes the cavity portion to enclose the cell assembly in the enclosure. In some embodiments, the sides of the central body comprise a first side and an optional second side opposing the first side, the first flap being coupled with the first side, the electrode being stacked along a stacking axis with the counter-electrode, the lid being planar in a plane parallel to the stacking axis, the first side and the optional second side being disposed along the stacking axis, and an optional second flap is coupled with and attached to the optional second side. In some embodiments, the first side is parallel to the electrode and to the counterelectrode. In some embodiments, the plane is of, or is parallel to, the lid of the enclosure. In some embodiments, the flaps are folded respectively along the fold lines and along the height direction. In some embodiments, the folds are folded along crease lines disposed along the vectorial component along the height direction. In some embodiments, the folds are folded along the crease lines disposed along the height direction. In some embodiments, the first flap is folded towards and is attached to a first side of the sides of the central body, the first flap being attached with the first side, the third flap is folded towards and is attached to a third side of the sides of the central body, and the fourth flap is folded towards and is attached to a fourth side of the sides of the central body. In some embodiments, the first fold and the second fold, are attached with the first flap such that the first fold and the second fold face each other. In some embodiments, the third side and the fourth side, are sides of the same plane of the central body. In some embodiments, the same plane comprises a curved plane. In some embodiments, the third side and the fourth side, are different sides of the central body opposing each other. In some embodiments, the first fold and the second fold, are attached with the third flap and the fourth flap, respectively, such that the first fold and the second fold, are attached to different sides of the central body opposing each other. In some embodiments, the extension comprises a second flap, the second flap being coupled (a) with the third flap by a third fold and (b) with the fourth flap by a fourth fold, the third fold and the fourth fold being attached with the second flap such that the third fold and the fourth fold face each other. In some embodiments, the third fold and the fourth fold, are attached with the third flap and the fourth flap, respectively, such that the third fold and the second fold, are attached to different sides of the central body opposing each other. In some embodiments, the first fold and the third fold face each other, and the second fold and the fourth fold face each other. In some embodiments, the second flap comprises the electrode terminal tab or the counter-electrode terminal tab. In some embodiments, the second flap is devoid of the electrode terminal tab and of the counterelectrode terminal tab. In some embodiments, the extension comprises a second flap opposing the first flap, the second flap being of the flaps folded respectively along the fold lines havingAttorney Docket No. ENX-0159.WO the vectorial component along the height direction, the flaps being folded towards respective sides of the central body. In some embodiments, the first side and a second side opposing the first side, are sides of the same plane of the central body. In some embodiments, the same plane comprises a curved plane. In some embodiments, the first side and the second side, are different sides of the central body opposing each other. In some embodiments, the cell assembly comprises the electrode separated from the counter-electrode by a separator disposed in the gap, the separator being configured to allow charge carriers to travel therethrough. In some embodiments, the charge carriers comprise alkali cations, alkali earth cations, any plurality of types thereof, or any combination thereof. In some embodiments, the separator comprises a porous layer. In some embodiments, the porous layer comprises alumina, boehmite, any combination thereof, or any plurality of types thereof. In some embodiments, the electrode comprises an active material comprising silicon. In some embodiments, the active material comprises silicon at a percentage of at least about 40% volume per volume. In some embodiments, the counter-electrode comprises an active material comprising a metal oxide. In some embodiments, the electrode and / or counter-electrode, comprise one or more allotropes of elemental carbon. In some embodiments, the cell assembly comprises a wound cell. In some embodiments, the cell assembly comprises a stack of unit cells stacked along a stacking axis. In some embodiments, the first side and an optional second side of the central body are stacked along the stacking axis. In some embodiments, each unit cell of the unit cells comprises the electrode and the counter-electrode. In some embodiments, the unit cells comprise at least 10 unit cells. In some embodiments, the unit cell has an aspect ratio of at least about 1 :2, 1 :5, 1 :10 or 1 :50 of a surface normal to the stacking axis, the surface being rectangular. In some embodiments, electrodes of the unit cells are coupled with an electrode busbar. In some embodiments, counter-electrodes of the unit cells are coupled with a counter-electrode busbar. In some embodiments, the electrode busbar and the counterelectrode busbar are disposed at different sides of the cell assembly. In some embodiments, the electrode busbar and the counter-electrode busbar are normal to the first side and / or to the second side. In some embodiments, a busbar is coupled with a terminal tab by a busbar extender, the busbar being the electrode busbar or the counter-electrode busbar, and the terminal tab being the electrode terminal tab or the counter-electrode terminal tab, respectively. In some embodiments, the busbar is coupled the busbar extender at least in part using welding. In some embodiments, the cell assembly is in a Euclidean geometric shape. In some embodiments, the cell assembly in in a Euclidean geometric shape of a rectangular prism, of a cylinder, or of a semicylinder. In some embodiments, the enclosure is hermetically sealed such that it is fluid sealed. In some embodiments, the fluid comprises a liquid, a gas, any plurality of types thereof, or any combination thereof. In some embodiments, the liquid comprises an electrolyte mixture. In some embodiments, the enclosure is hermitically sealedAttorney Docket No. ENX-0159.WO at least in part by being configured to be heat sealed and / or pressure sealed. In some embodiments, the enclosure comprises one or more layers. In some embodiments, the one or more layers comprise a layer configured to prevent harmful amount of reactive species from propagating from an ambient atmosphere external to the enclosure, into an interior of the enclosure, the harmful amount being harmful to the cell assembly, to the device, to a user of the device, to a facility in which the device is disposed, or any combination thereof; wherein the reactive species comprise water, oxygen, hydrogen sulfide, or any combination thereof. In some embodiments, the reactive species comprise water. In some embodiments, a level of the reactive species is at least about 1 , 1.5, 2, 2.5, 3, or 4 orders of magnitude lower than in an ambient environment external to the enclosure. In some embodiments, the level of the reactive species is at most about 10 ppm, 100ppm, 300ppm, 500ppm, or WOOppm. In some embodiments, the layer(s) comprise at least one layer of organic material and at least one layer of a metallic material. In some embodiments, the organic material comprises a polymer, a resin, a copolymer, a mixture of polymers, any plurality of types thereof, or any combination thereof. In some embodiments, the metallic material comprises elemental metal, metal alloy, any plurality of type thereof, or any combination thereof. In some embodiments, the enclosure comprises a metallic layer. In some embodiments, the enclosure is a pouch. In some embodiments, the organic material comprises nylon, polyester, polyamide (PA), polyolefin, nitrile rubber (NBR), any plurality of types thereof, or any combination thereof. In some embodiments, the polyester comprises poly ethyl terephthalate. In some embodiments, the nylon comprises a polyphthalamide, an oil-filled nylon, any plurality of types thereof, or any combination thereof. In some embodiments, the polyolefin comprises polyethylene or polypropylene. In some embodiments, the organic material is processed via a cast film extrusion method. In some embodiments, the organic material is configured to withstand a chemistry of the cell assembly throughout its prescribed use and / or lifetime. In some embodiments, the one or more layers comprises an exterior facing layer facing an exterior environment to the enclosure and an interior facing layer facing an interior space of the enclosure. In some embodiments, the exterior facing layer has a higher seal strength and / or toughness, as compared to an interior facing layer. In some embodiments, the interior facing layer is more easily heat sealable as compared to the exterior facing layer. In some embodiments, an interlayer peel strength of the one or more layers is at least about 15 Newtons divided by 15 millimeters (>15 N / 15mm). In some embodiments, the one or more layers have a high sealing strength of at least about 20N / 15mm, 50N / 15mm, 70N / 15mm, or 90N / 15mm. In some embodiments, the one or more layers have a high friction coefficient of at most about 0.3. In some embodiments, a first thickness of a first organic layer of the organic layers is thicker than a second thickness of a second organic layer of the organic layers. In some embodiments, the first organic layer and the second organic layer are layers of organicAttorney Docket No. ENX-0159.WO material. In some embodiments, the second organic layer is the exterior facing layer. In some embodiments, the second organic layer is the interior facing layer. In some embodiments, the metallic layer and at least one of the organic layers has (e.g., substantially) the same thickness. In some embodiments, the one or more layers have a Water Vapor Transmission Rate (WVTR) of at most about 0.05 grams per meter squared per day (gr / m2 / day), 0.1 gr / m2 / day, 0.15 gr / m2 / day, 0.2 gr / m2 / day, or 0.5 gr / m2 / day. In some embodiments, the one or more layers are layers, and wherein the layers have a water vapor transmission rate of at least about 1 , 2, or 3 orders of magnitude lowerthan one or more of the organic layers alone. In some embodiments, the enclosure comprises one or more layers having a thickness, and the folds are configured to increase the thickness by at most about 4 times the thickness, or 3 times the thickness. In some embodiments, the enclosure comprises a first portion adhered to a second portion. In some embodiments, the enclosure comprises a cavity portion closed by a lid portion. In some embodiments, the cavity portion assumes a cavity shape configured to accommodate a volume of the cell assembly, and the lid portion is planar and closes the cavity portion to enclose the cell assembly in the enclosure. In some embodiments, the electrode is stacked along a stacking axis with the counter-electrode, the lid being planar in a plane parallel to the stacking axis, and the first side and a second side being disposed along the stacking axis, the second side opposing the first side. In some embodiments, the first side and the second side are parallel to the electrode and to the counter-electrode. In some embodiments, the plane is of, or is parallel to, the lid of the enclosure. In some embodiments, the extension comprises a second flap, the electrode terminal tab being disposed in the first flap or in the second flap, and wherein the counter-electrode terminal tab is disposed in the first flap or in the second flap. In some embodiments, the electrode terminal tab and the counter-electrode terminal tab, are disposed in a flap of the flaps. In some embodiments, the electrode terminal tab and the counter-electrode terminal tab are disposed in different flaps. In some embodiments, each of the electrode terminal tab and the counter-electrode terminal tab are disposed in a grommet operatively coupled with the extension of the enclosure to at least in part allow the hermetic sealing of the enclosure. In some embodiments, the electrode terminal tab is coupled with an electrode busbar coupled with the electrode. In some embodiments, the counter-electrode terminal tab is coupled with a counter-electrode busbar coupled with the counter-electrode. In some embodiments, the electrode busbar and the counter-electrode busbar are disposed in the central body of the enclosure. In some embodiments, the terminal tabs are bent to be at most at a plane of an external surface of the folds. In some embodiments, the terminal tabs are each bent to have a distal portion in a plane parallel to the lid. In some embodiments, the cell assembly is coupled with a constraint system configured to curb volumetric change of the cell assembly during a prescribed operation of the device, the constraint system being disposed in the central body of the enclosure. In some embodiments, the constraint system isAttorney Docket No. ENX-0159.WO configured to allow flow of charge carriers therethrough, the charge carriers participating in the energy manipulation of the device. In some embodiments, the constraint system is configured to house the cell assembly in an interior space of the constraint system. In some embodiments, the constraint system is configured to allow a charge carrier precursor to adhere onto an external side of the constraint away from the interior space of the constraint system. In some embodiments, the device is configured to allow in situ generation of charge carriers from the charge carrier precursor disposed in the central body of the enclosure while the enclosure is hermetically sealed. In some embodiments, the device is configured to allow control of a pace of charge carriers generated from the charge carrier precursor disposed in the central body of the enclosure while the enclosure is hermetically sealed, the control of the pace being of a generation pace and / or of a diffusion pace. In some embodiments, the constraint system comprises a metallic material. In some embodiments, the constraint is coupled with a pouch protection layer (PPL) disposed in the central body. In some embodiments, the PPL comprises a polymer, a resin, any plurality of types thereof, or any combination thereof. In some embodiments, the PPL is disposed parallel to sides of the central body. In some embodiments, the PPL is configured to provide a mechanical cushion between the constraint and the enclosure. In some embodiments, the PPL is configured to hinder rupture of the enclosure during a prescribed operation of the device and / or standard testing of the device according to applicable jurisdictional and / or industrial standardized testing of the device. In some embodiments, the rupture comprises cracking. In some embodiments, the sides comprise a curved side onto which the third flap and the fourth flap are folded. In some embodiments, the curved side is of a cylindrical central body or of a semi-cylindrical central body. In some embodiments, the sides comprise a first side, a second side, a third side and a fourth side. In some embodiments, the central body is a box. In some embodiments, the box is a cube. In some embodiments, the box is different from a cube. In some embodiments, one or more of the folds are truncated. In some embodiments, the folds are truncated. In some embodiments, the central body comprises a second side opposing the first side; and wherein the extension comprises a second flap; and wherein (a) when unfolded, the first fold and the second fold, extend the first flap along a lateral direction, the first side having a vertical height normal to the lateral direction, the first flap extending at most to a vertical height, and (b) when unfolded, a third fold and a fourth fold, extend the second flap along the lateral direction, the second side having the vertical height normal to the lateral direction, the second flap extending at most to the vertical height. In some embodiments, the sides of the central body comprise a third side and a fourth side. In some embodiments, (a) when unfolded, the first fold and the fourth fold, extend the third flap along a longitudinal direction, the third side having the vertical height normal to the longitudinal direction, the third flap extending at most to the vertical height, and (b) when unfolded, the third fold and the second fold, extend the fourth flap along theAttorney Docket No. ENX-0159.WO longitudinal direction, the fourth side having the vertical height normal to the longitudinal direction, the fourth flap extending at most to the vertical height. In some embodiments, (a) the electrode terminal tab and the counter-electrode terminal tab are folded with one or more of the flaps in which they are disposed, (b) the central body comprises a front side opposing a back side disposed at least partially in a plane, the electrode terminal tab and the counterelectrode terminal tab being folded from the back side to the front side, the electrode terminal tab and the counter-electrode terminal tab emerging from the enclosure from the front side, or (c) a combination of (a) and (b). In some embodiments, the extension comprises a second flap opposing the first flap, and the central body comprises a second side opposing the first side of the sides; and wherein (a) the third flap is folded onto and adhered with the third side using a first adhesive type, (b) the fourth flap is folded onto and adhered with the fourth side with the first adhesive type, (c) the first flap is folded onto and adhered with the first side with the first adhesive type, and (d) the second flap is folded onto and adhered with the second side with the first adhesive type; and wherein (i) the first fold and the second fold are folded onto and adhered with the first flap using a second adhesive type, and (ii) a third fold and a fourth fold are folded onto and adhered with the second flap using the second adhesive type. In some embodiments, the first adhesive type is the second adhesive type. In some embodiments, the first adhesive type is different from the second adhesive type. In some embodiments, the first adhesive type and / or the second adhesive type, comprise a standalone adhesive, a tape, any plurality of types thereof, or any combination thereof. In some embodiments, the standalone adhesive is configured for application as a fluid or as a semisolid. In some embodiments, the tape is a double sided tape. In some embodiments, the tape is a single sided tape. In some embodiments, the first adhesive type and / or the second adhesive type is configured to be cured. In some embodiments, the curing comprises an electromagnetic curing. In some embodiments, the curing comprises infrared and / or ultraviolet curing. In some embodiments, the curing comprises irradiative curing, chemical curing, or any combination thereof. In some embodiments, the curing comprises polymerization. In some embodiments, the curing comprises pressure treatment. In some embodiments, the curing comprises exposure to at least one type of curing gas. In some embodiments, the first adhesive type and / or second adhesive type, is configured to hinder rupture of the enclosure during a prescribed operation of the device and / or standard testing, according to applicable jurisdictional and / or industrial standardized testing, of the device. In some embodiments, the rupture comprises cracking. In some embodiments, the device further comprises a cushion coupled with the enclosure, the cushion being configured to hinder rupture of the enclosure during a prescribed operation of the device and / or standard testing, according to applicable jurisdictional and / or industrial standardized testing, of the device. In some embodiments, the cushion is adhered with the enclosure using an adhesive of the first adhesive type, the second adhesive type, or anotherAttorney Docket No. ENX-0159.WO adhesive type. In some embodiments, the cushion is welded with the enclosure. In some embodiments, the device is configured to hinder rupture of the enclosure during a prescribed operation of the device and / or standard testing according to applicable jurisdictional and / or industrial standardized testing, of the device; wherein the device is configured to seal chemicals in the enclosure during the prescribed operation of the device and / or the standard testing. In some embodiments, the chemicals comprise solids, liquids, gas, any plurality of types thereof, or any combination thereof. In some embodiments, the liquids comprise an electrolytic mixture. In some embodiments, the solids comprise one or more powder types. In some embodiments, the solids comprise active materials of the electrode and of the counterelectrode. In some embodiments, the rupture comprises cracking. In some embodiments, the central body comprises a second side opposing the first side; and wherein the enclosure is configured to be enclosed in a cavity of a target device such that a controller of the energy manipulation device is coupled with the device externally to contact the enclosure such that it is parallel to one or more of the sides of the central body with which the flaps adhere. In some embodiments, the controller is configured to reversibly couple and uncouple with the device. In some embodiments, the central body comprises a second side opposing the first side. In some embodiments, the enclosure is configured to be enclosed in a cavity of a target device such that a controller of the energy manipulation device is coupled with the device externally to contact the enclosure such that it is parallel to a side different from the sides of the central body with which the flaps adhere. In some embodiments, the controller is configured to reversibly couple and uncouple with the device. In some embodiments, the cell assembly is an electrochemical cell assembly. In some embodiments, the device comprises a battery. In some embodiments, the device comprises a rechargeable battery. In some embodiments, the device comprises a lithium-ion battery. In some embodiments, the energy manipulation comprises cycling between a charged state and a discharged state. In some embodiments, the cycling comprises at least about 200, 400, 500, 800, 1000, 1200, or 1500 cycles of charge and discharge.

[0015] In another aspect, a method of the energy manipulation, the method comprises: (a) providing the any of the aforementioned devices, and (b) storing, transporting, servicing, upgrading, and / or using the device for the energy manipulation. In some embodiments, using the device comprises buffering the device and / or generating a passivation layer in the electrode and / or in the counter-electrode. In some embodiments, using the device comprises controlling the device to maximally prolong its lifetime.

[0016] In another aspect, a method of generating the any of the aforementioned devices, the method comprises: using one or more operations to generate the device. In some embodiments, generating the device comprises manufacturing the device. In some embodiments, the one or more operations comprise roll to roll manufacturing. In someAttorney Docket No. ENX-0159.WO embodiments, the one or more operations comprise heat and / or pressure treating the device to seal the enclosure while the cell assembly is in the enclosure. In some embodiments, the one or more operations comprise injecting a liquid electrolyte in the enclosure to seal the electrolyte in the enclosure while the cell assembly is in the enclosure.

[0017] In another aspect, an apparatus for the energy manipulation, the apparatus comprises: one or more controllers configured to (a) operatively couple with the any of the aforementioned devices, and (b) direct one or more components to store, transport, serve, upgrade, and / or use the device for the energy manipulation. In some embodiments, the one or more controllers are configured to (a) direct buffering of the device and / or (b) direct generation of a passivation layer in the electrode and / or in the counter-electrode of the device. In some embodiments, using the one or more controllers are configured to control use of the device to maximally prolong its lifetime. In some embodiments, the one or more controllers are configured to operatively couple with a power source and / or with a communication platform. In some embodiments, one or more of the at least one component is of the device.

[0018] In another aspect, an apparatus for the energy manipulation, the apparatus comprises: one or more controllers configured to direct one or more components to generate the any of the aforementioned devices. In some embodiments, the one or more components comprise roll to roll manufacturing machinery. In some embodiments, the one or more components comprise (a) a heater configured to heat the extension of the enclosure and / or (b) pressure applicators configured to apply pressure on the extension of the enclosure, the heater and / or the pressure applicators configured to seal the enclosure while the cell assembly is in the enclosure. In some embodiments, the one or more components are configured to inject a liquid electrolyte in the enclosure to seal the electrolyte in the enclosure while the cell assembly is in the enclosure. In some embodiments, the one or more controllers are configured to operatively couple with a power source and / or with a communication platform. In some embodiments, one or more of the at least one component is of the device.

[0019] In another aspect, non-transitory computer-readable program instructions physically inscribed on at least one media, the program instructions, when read by one or more processors operatively coupled with the any of the aforementioned devices, cause the one or more processors to execute one or more operations for storing, transporting, servicing, upgrading, and / or using the device for the energy manipulation. In some embodiments, using the device comprises buffering the device and / or generating a passivation layer in the electrode and / or in the counter-electrode. In some embodiments, using the device comprises controlling the device to maximally prolong its lifetime.

[0020] In another aspect, non-transitory computer-readable program instructions physically inscribed on at least one media, the program instructions, when read by one or more processors operatively coupled with the any of the aforementioned devices, cause the one orAttorney Docket No. ENX-0159.WO more processors to execute one or more operations for generating the device for use in the energy manipulation. In some embodiments, generating the device comprises manufacturing the device. In some embodiments, the one or more operations comprise roll to roll manufacturing. In some embodiments, the one or more operations comprise heat and / or pressure treating the device to seal the enclosure while the cell assembly is in the enclosure. In some embodiments, the one or more operations comprise injecting a liquid electrolyte in the enclosure to seal the electrolyte in the enclosure while the cell assembly is in the enclosure.

[0021] In another aspect, a system for effectuating the methods, operations of an apparatus, and / or operations inscribed by non-transitory computer readable program instructions (e.g., inscribed on a media / medium), disclosed herein.

[0022] In another aspect, a system for effectuating the methods, operations of an apparatus, operation of a device, and / or operations inscribed by non-transitory computer readable program instructions (e.g., inscribed on a media / medium), disclosed herein.

[0023] In another aspect, device(s) (e.g., apparatus) for effectuating the methods, operations of an apparatus, and / or operations inscribed by non-transitory computer readable program instructions (e.g., inscribed on a media / medium).

[0024] In other aspects, systems, apparatuses (e.g, controller(s)), and / or non-transitory computer-readable program instructions (e.g., software) that implement any of the methods disclosed herein. In some embodiments, the program instructions are inscribed on at least one medium (e.g., on a medium or on media).

[0025] In other aspects, methods, systems, apparatuses (e.g., controller(s)), and / or non- transitory computer-readable program instructions (e.g., software) that implement any of the devices disclosed herein and / or any operation of these devices. In some embodiments, the program instructions are inscribed on at least one medium (e.g., on a medium or on media).

[0026] In another aspect, an apparatus comprises at least one controller that is configured (e.g., programmed) to direct a mechanism used in a methodology disclosed herein to implement (e.g., effectuate) any of the method and / or operations disclosed herein, wherein the controller(s) is operatively coupled with the mechanism. In some embodiments, the controller(s) implements any of the methods and / or operations disclosed herein. In some embodiments, the at least one controller comprises, or be operatively coupled with, a hierarchical control system. In some embodiments, the hierarchical control system comprises at least three, four, or five, control levels. In some embodiments, at least two operations are performed, or directed, by the same controller. In some embodiments, at least two operations are each performed, or directed, by a different controller.

[0027] In another aspect, an apparatus comprises at least one controller configured (e.g., programmed) to implement (e.g., effectuate), or direct implementation of the method, process,Attorney Docket No. ENX-0159.WO and / or operation disclosed herein. In some embodiments, the at least one controller implements any of the methods, processes, and / or operations disclosed herein.

[0028] In another aspect, non-transitory computer readable program instructions, when read by one or more processors, are configured to execute, or direct execution of, the method, process, and / or operation disclosed herein. In some embodiments, the at least one controller implements any of the methods, processes, and / or operations disclosed herein. In some embodiments, at least a portion of the one or more processors is part of a mechanism, outside of the mechanism, or in a location remote from the mechanism disclosed herein (e.g., in the cloud).

[0029] In another aspect, a system comprises an apparatus and at least one controller configured (e.g., programmed) to direct operation of the apparatus, wherein the at least one controller is operatively coupled with the apparatus. In some embodiments, the apparatus includes any apparatus or device disclosed herein. In some embodiments, the at least one controller implements, or direct implementation of, any of the methods disclosed herein. In some embodiments, the at least one controller directs any apparatus (or component thereof) disclosed herein. In some embodiments, at least two operations (e.g., instructions) of the apparatus are directed by the same controller. In some embodiments, at least two operations (e.g., instructions) of the apparatus are directed by different controllers. In some embodiments, at least two operations (e.g., instructions) are carried out by the same processor and / or by the same sub-computer software product. In some embodiments, at least two of operations (e.g., instructions) are carried out by different processors and / or by different sub-computer software products.

[0030] In another aspect, a computer software product, comprising a (e.g., non-transitory) computer-readable medium / media in which program instructions are stored, which instructions, when read by a computer, cause the computer to direct a mechanism used to implement (e.g., effectuate) any of the method disclosed herein, wherein the non-transitory computer-readable medium is operatively coupled with the mechanism. In some embodiments, the mechanism comprises an apparatus or an apparatus component.

[0031] In another aspect, a computer system comprising one or more computer processors and non-transitory computer-readable medium / media coupled thereto. In some embodiments, the non-transitory computer-readable medium / media comprises machine-executable code that, upon execution by the one or more computer processors, implements any of the methods and / or operations (e.g., as disclosed herein), and / or effectuates directions of the controller(s) (e.g., as disclosed herein).

[0032] In another aspect, a method comprises executing one or more operations associated with at least one configuration of the mechanism(s) (e.g., device(s)) disclosed herein.Attorney Docket No. ENX-0159.WO

[0033] In another aspect, an apparatus comprises at least one controller is configured (i) operatively couple to the device, and (ii) direct executing one or more operations associated with at least one configuration of the device(s) disclosed herein.

[0034] In another aspect, at least one controller is associated with the methods, devices, and software disclosed herein. In some embodiments, the at least one controller comprises at least one connector configured to connect to a power source. In some embodiments, the at least one controller being configured to operatively couple with a power source at least in part by (I) having a power socket and / or (II) being configured for wireless power transfer using inductive charging. In some embodiments, the at least one controller comprises a non-volatile memory, e.g., a solid-state device (SSD) such as a FLASH memory. In some embodiments, the at least one controller is included in, or comprises, a hierarchical control system. In some embodiments, the hierarchical control system comprises at least three hierarchical control levels. In some embodiments, the at least one controller is included in a control system disclosed herein. In some embodiments, the at least one controller is configured to control at least one other component of a mechanism (e.g., system, device, or apparatus) disclosed herein. In some embodiments, the device disclosed herein is a component of a system, and wherein the at least one controller is configured to (i) operatively couple to another component of the system and (ii) direct operation of the other component. In some embodiments, the at least one controller is configured to direct operation of the other component at least in part for participation of the other component in a method disclosed herein.

[0035] In another aspect, non-transitory computer readable program instructions for a method disclosed herein, the non-transitory computer readable program instructions, when read by one or more processors operatively coupled with the device, cause the one or more processors to direct executing one or more operations associated with at least one configuration of the device(s) disclosed herein.

[0036] In some embodiments, the program instructions are of a computer product.

[0037] The various embodiments in any of the above aspects are combinable (e.g., within an aspect), as appropriate. Individual features (e.g., embodiments) disclosed herein are combinable in any manner requested and / or desired, as applicable.

[0038] Additional aspects and advantages of the present disclosure will become readily apparent to those skilled in this art from the following detailed description, wherein only illustrative embodiments of the present disclosure are shown and described. As will be realized, the present disclosure is capable of other and different embodiments, and its several details are capable of modifications in various obvious respects, all without departing from the disclosure. Accordingly, the drawings and description are to be regarded as illustrative in nature, and not as restrictive.Attorney Docket No. ENX-0159.WOINCORPORATION BY REFERENCE

[0039] All publications, patents, and patent applications mentioned in this specification are herein incorporated by reference to the same extent as if each individual publication, patent, or patent application was specifically and individually indicated to be incorporated by reference.

[0040] It should be appreciated that any patent, publication, or other disclosure material, in whole or in part, which is said to be incorporated by reference herein is incorporated herein only to the extent that the incorporated material does not conflict with existing definitions, statements, or other disclosure material set forth in this disclosure. As such, and to the extent necessary, the disclosure as explicitly set forth herein supersedes any conflicting material incorporated herein by reference. Any material, or portion thereof, that is said to be incorporated by reference herein, but which conflicts with existing definitions, statements, or other disclosure material set forth herein will only be incorporated to the extent that no conflict arises between that incorporated material and the existing disclosure material.BRIEF DESCRIPTION OF THE DRAWINGS

[0041] The present disclosure, in accordance with one or more various implementations, is described in detail with reference to the following drawings. The drawings are provided for purposes of illustration only and merely depict typical or example implementations. These drawings are provided to facilitate an understanding of the concepts disclosed herein and should not be considered limiting of the breadth, scope, or applicability of these concepts. It should be noted that for clarity and ease of illustration, these drawings are not necessarily made to scale.

[0042] The novel features of the present disclosure are set forth with particularity in the appended claims. Each of the figures disclosed herein is shown in accordance with some implementations of the subject matter of the disclosure. A better understanding of the features and advantages of the present disclosure will be obtained by reference to the following detailed description that sets forth illustrative embodiments, in which the principles of the present disclosure are utilized, and the accompanying drawings or figures (also “Fig.” and “Figs.” herein), of which:

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

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

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

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

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

[0048] Fig. 6 depicts schematic perspective views of device (e.g., battery) components;

[0049] Fig. 7 schematically shows various devices shown as cross sections;

[0050] Fig. 8 depicts a schematic example of a device during its fabrication;Attorney Docket No. ENX-0159.WO

[0051] Fig. 9 depicts schematic examples of a device during its fabrication operations;

[0052] Fig. 10 depicts schematic examples of devices during their fabrication;

[0053] Fig. 11 depicts schematic examples of devices during their fabrication;

[0054] Fig. 12 depicts a schematic example of a device during its fabrication;

[0055] Fig. 13 depicts a schematic example of a device portions during the device fabrication;

[0056] Fig. 14 depicts schematic examples of a device at different views;

[0057] Fig. 15 depicts a schematic example view of a device;

[0058] Fig. 16 depicts photographs of a device at different views;

[0059] Fig. 17 depicts photographs of a device portions at different views;

[0060] Fig. 18 is an illustrative chart showing improvement in energy density for secondary batteries with folded terrace cells, in accordance with some implementations of the disclosure; and an illustrative chart showing the volume reduction for secondary batteries, in accordance with some implementations of the disclosure;

[0061] Fig. 19 presents illustrative charts showing the length changes of secondary batteries in different dimensions, in accordance with some implementations of the disclosure;

[0062] Fig. 20 is an illustrative chart showing discharge capacity change for secondary batteries, in accordance with some implementations of the disclosure;

[0063] Fig. 21 shows schematic representation of X-ray images of a secondary battery, the X-ray images shown in Fig. 30;

[0064] Fig. 22 shows another illustrative diagram of a secondary battery, in accordance with some implementations of the disclosure;

[0065] Fig. 23 shows another illustrative diagram of a secondary battery, in accordance with some implementations of the disclosure;

[0066] Fig. 24 shows an illustrative diagram of a pack integration for a secondary battery with non-folded terrace, in accordance with some implementations of the disclosure;

[0067] Fig. 25 shows an illustrative diagram of a pack integration for a secondary battery with folded terrace, in accordance with some implementations of the disclosure;

[0068] Fig. 26 shows another illustrative diagram of a secondary battery, in accordance with some implementations of the disclosure;

[0069] Fig. 27 depicts example flow chart depicting a process for generating the device;

[0070] Fig. 28 depicts a schematic example of a control system;

[0071] Fig. 29 depicts a schematic example of a processing system; and

[0072] Fig. 30 shows X-ray images of a secondary battery, in accordance with some implementations of the disclosure.Attorney Docket No. ENX-0159.WO

[0073] The figures and components therein may not be drawn to scale. Various components of the figures described herein may not be drawn to scale. For clarity and ease of illustration, these drawings are not necessarily made to scale.DETAILED DESCRIPTION

[0074] While various embodiments of the inventions have been shown, and described herein, it will be obvious to those skilled in the art that such embodiments are provided by way of example only. Numerous variations, changes, and substitutions may occur to those skilled in the art without departing from the invention. It should be understood that various alternatives to the embodiments of the invention described herein might be employed. The various embodiments, aspects, examples, variations, alternates, and instances, disclosed herein are combinable, as appropriate.

[0075] Reference throughout the specification to “various embodiments,” “some embodiments,” “one embodiment,” “some example embodiments,” “one example embodiment,” “an example,” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with any embodiment is included in at least one embodiment. Thus, appearances of the phrases “in various embodiments,” “in some embodiments,” “in one embodiment,” “some example embodiments,” “one example embodiment,” or “in an embodiment” in places throughout the specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures or characteristics may be combined in any suitable manner in one or more embodiments.

[0076] Terms such as “a,” “an” and “the” are not intended to refer to only a singular entity but include the general class of which a specific example may be used for illustration. The terminology herein is used to describe specific embodiments in the present disclosure, but their usage does not delimit to the specific embodiments of the present disclosure. The term “includes” means includes but not limited to, the term “including” means including but not limited to, and the term “based on” means based at least in part on.

[0077] An immediately consecutive second feature to a first feature is devoid of another feature disposed therebetween, the features being of the same type. The feature can be a real-life feature, a calculated feature, or any other virtual feature.

[0078] When ranges are mentioned, the ranges are meant to be inclusive, unless otherwise specified. For example, a range between value 1 and value 2 is meant to be inclusive and include value 1 and value 2. The inclusive range will span any value from about value 1 to about value 2. The term “adjacent” or “adjacent to,” as used herein, includes “next to,” “adjoining,” “in contact with,” and “in proximity to.” When ranges are mentioned (e.g., between, at least, at most, and the like) the endpoint(s) of the range is / are also claimed. For example, when the range is from X to Y, the values of X and Y are also claimed. For example, when theAttorney Docket No. ENX-0159.WO range is at most Z, the value of Z is also claimed. For example, when the range is at least W, the value of W is also claimed.

[0079] When the term “about” is used in the contacts of a number, e.g., “about #,” the term includes the number.

[0080] The conjunction “and / or” as used herein in “X and / or Y” - including in the specification and claims - is meant to include the options (i) X, (ii) Y, and (iii) X and Y, as applicable. The phrase “including X, and / or Y” is meant to have the same meaning as the phrase “comprising X or Y” under currently prevailing US law.

[0081] The term “operatively coupled,” “operatively configured,” or “operatively connected” refers to a first mechanism that is coupled (or connected) to a second mechanism to allow the intended operation of the second and / or first mechanism. The coupling may comprise physical or non-physical coupling. The non-physical coupling may comprise signal-induced coupling (e.g., wireless coupling).

[0082] The phrase “is / are structured” or “is / are configured,” when modifying an article, refers to a structure of the article that can bring about the referred result.

[0083] The symbol designates the mathematical operation of multiplication, e.g., “times."

[0084] Fundamental length scale (abbreviated herein as “FLS”) comprises any suitable scale (e.g., dimension) of an object. For example, an FLS of an object may comprise a length, a width, a height, a diameter, a spherical equivalent diameter, a diameter of a bounding circle, a diameter equivalent of a bounding sphere.

[0085] Performing a reversible first operation is understood herein to mean performing the first operation and being capable of performing the opposite operation to that first operation (e.g., which is a second operation). For example, when a controller directs reversibly opening a shutter, that shutter can also close, and the controller can optionally direct a closure of that shutter. For example, when an attractor reversibly binds to a charge carrier, that attractor can also release that charge carrier after its binding.

[0086] While the disclosure refers to a cathode as an electrode, the electrode may be an anode, as applicable.

[0087] While various portions herein may refer for simplicity to a battery as an energy manipulation device, that disclosure is extended to any another energy manipulation (e.g., storage) device, as applicable. The present disclosure can relate to (e.g., secondary) batteries, the structures that make up the batteries, and the methods and processes for manufacturing the structures and batteries. As used herein, the term “anode” used in the context of a battery may refer to the negative electrode in a battery. “Anode material” or “anodically active” as used herein may refer to a material or materials suitable for use as the negative electrode of a battery. The term “cathode” as used herein in the context of a battery may refer to the positiveAttorney Docket No. ENX-0159.WO electrode in a battery. “Cathode material” or “cathodically active” as used herein may refer to a material or materials suitable for use as the positive electrode of a battery.

[0088] In some implementations described herein, the term “electrode” may be used to refer to either the anode or the cathode, and the term “counter-electrode” may refer to the other or opposite. For the sake of explanation, implementations may be described in terms of “electrode” and “counter-electrode.” It should be appreciated that in these implementations, the term electrode may be replaced by the term anode while the term counter-electrode may be replaced by the term cathode, as applicable. Alternatively, in these implementations, the term electrode may be replaced by the term cathode while the term counter-electrode may be replaced by the term anode, as applicable.

[0089] The prescribed use of the device (e.g., battery) comprises during charge-discharge cycling, during transportation, during storage, during maintenance, during upgrade, or any combination thereof. The prescribed use (e.g., operation) of the cell assembly comprises during formation of the cell assembly, during buffering of the cell assembly, during the prescribed use of the device comprising the cell assembly or any combination thereof.

[0090] In some embodiments, the energy manipulation device may comprise at least one battery. The battery may comprise one or more cells. The battery may be a rechargeable battery, e.g., a secondary battery. The charge carriers of the battery may comprise alkali earth, alkali cations, a plurality of types of any thereof, or any combination thereof. In an example, the battery comprises charge carriers such as lithium charge carriers.

[0091] In some embodiments, the energy manipulation device may comprise at least one battery. The battery may comprise one or more cells. The battery may be a rechargeable battery, e.g., a secondary battery. The charge carriers of the battery may comprise alkali earth, alkali cations, a plurality of types of any thereof, or any combination thereof. In an example, the battery comprises charge carriers such as lithium charge carriers. In some embodiments, charge carriers may comprise carrier ions. In some embodiments, carrier ions are provided to positive electrodes and / or negative electrodes by carrier ion supply layers. Carrier ion supply layers may comprise one or more sources of lithium ions, sodium ions, potassium ions, calcium ions, magnesium ions, aluminum ions, and / or similar such ions. The battery may or may not be a polymer type battery such as a lithium polymer type battery.

[0092] In some embodiments, the energy manipulation device includes at least one unit cells. The energy manipulation device may comprise a population of unit cells (e.g., also referred to herein as a “set of cells”) . The device may comprise an electrode connector operatively coupled with the electrode and a counter-electrode connector operatively coupled with the counterelectrode, with operatively coupled comprising electrically connected. The electrode connector may be also referred to herein as “an electrode terminal,” and the counter-electrode connector may be also referred to herein as “a counter-electrode terminal.” The device may comprise anAttorney Docket No. ENX-0159.WO electrode busbar, a counter-electrode busbar, an electrode terminal operatively coupled with the electrode busbar, and a counter-electrode terminal operatively coupled with the counterelectrode busbar. The electrode and counter electrode of the unit cell are separated by each other by a gap, e.g., to electrically separate the electrode from the counter-electrode. The gap may include a separator configured to (a) electrically isolate the electrode from the counter electrode and (b) allow traversal of charge carriers through the separator. In some embodiments, each unit cell of the set of cells, includes an electrode structure and a counterelectrode structure separated from each other by a gap. One or more (e.g., each) cells of the set of cells, each include a separator disposed in the gap. In some embodiments, the battery includes adjacent electrode sub-units. Each of the electrode sub-units has a dimension in the X-axis, Y-axis and Z-axis, respectively. The X-axis, Y-axis and Z-axis are each mutually perpendicular, akin to a Cartesian coordinate system. As used herein, dimensions of each electrode sub-unit in the Z-axis may be referred to as a "height", dimensions in the Y-axis may be referred to as a "length" and dimensions in the X-axis may be referred to as a "width." The electrode sub-units may be combined into one or more unit cells. A cell can include (a) at least one anodically active material mass (e.g., layer) and / or (b) at least one cathodically active material mass (e.g., layer). In some embodiments, the anodically active material is separated from the cathode by the gap. In some embodiments, the cathodically active material is separated from the anode by the gap. In some embodiments, the cathodically active material is separated from the anodically active material by the gap. The set of cells may comprise at least 2, 10, 20, 50, 100, 150, 200, 250, or 500 cells. The set of cells may comprise any number of cells between any of the aforementioned number of cells, e.g., from 2 to 500 cells, or from 50 to 500 cells. An active material mass may operatively couple to a current collector. The active material mass may comprise one or more layers. The active material may form a gradient.

[0093] In some embodiments, the device includes an electrode busbar and a counterelectrode busbar. The electrode busbar can be operatively coupled with (e.g., electrically connected with) the electrode, e.g., via electrode tab. The counter-electrode busbar is operatively coupled with (e.g., electrically connected with) the counter-electrode, e.g., via counter-electrode tab. The electrode busbar can be operatively coupled with the electrodes of the set of cells, e.g., via electrode tabs. The counter-electrode busbar is operatively coupled with the counter-electrodes of the set of cells, e.g., via counter-electrode tabs. An electrode tab can be an extension of the electrode that is devoid of the electrode active material. A counter-electrode tab can be an extension of the counter-electrode that is devoid of the counter-electrode active material.

[0094] In some embodiments, the device includes a first busbar and a second busbar that are in electrical contact with the anode(s) and the cathode(s), respectively, e.g., via electrode tabs.Attorney Docket No. ENX-0159.WOThe electrode tabs on the first side of the stack of cells can be electrically coupled with the first busbar, which may be referred to as an anode busbar. The electrode tabs on the second side of the stack of cells may be electrically coupled with the second busbar, which may be referred to as a cathode busbar. In some embodiments, the first busbar is electrically coupled with a first electrical terminal of the secondary battery, which is electrically conductive. When the first busbar comprises an anode busbar for the device (e.g., battery), the first electrical terminal comprises a negative terminal. In some embodiments, the second busbar is electrically coupled with a second electrical terminal of the device, which is electrically conductive. When the second busbar comprises a cathode busbar for the device, the second electrical terminal comprises a positive terminal of the device.

[0095] In some embodiments, the cell may be coupled with a (e.g., solid) busbar. In some embodiments, the set of cells may be coupled with the (e.g., solid) busbar. The busbar may comprise a (e.g., solid) material of a class. The material class may include an elemental metal, a metal alloy, or an allotrope of elemental carbon, any plurality of types thereof, or any combination thereof. The busbar may comprise (e.g., solid) material, e.g., including one or more types of materials. At least two types of materials may belong to the same class of materials. At least two types of materials may belong to different classes of materials. A class of material may be a composite or a non-composite material. A class of material may be a tacky material (e.g., a tacky connector), or a solid material (e.g., that is non-tacky). A class of material may be a material that is fluid, or non-fluid, e.g., during manufacture of the energy manipulation device such as a battery. In an example, the (e.g., solid) busbar may comprise a metal alloy and an elemental metal. In an example, the (e.g., solid) busbar may comprise two types of metal alloys. In an example, the (e.g., solid) busbar may comprise a composite material and a non-composite material. The busbar may comprise any conductive material disclosed herein. In an example, the busbar includes copper (e.g., Cu101) and Inconel (e.g., N178). The material class can be an oxygen free material. The material class may be an electronic grade material.

[0096] In some embodiments, a busbar is attached to the current collector tabs, e.g., the attachment being assisted by the tacky connector. In an example, the busbar contacts the tacky connector that contacts the tab(s). The busbar may have a cross section of a Euclidean shape, e.g., a vertical cross section. The busbar may have a cross section of a geometric planar shape, e.g., a vertical cross section. The shape may include a polygon, an ellipse, any combination thereof and / or a plurality thereof. The polygon may include a rectangle, or a plurality of rectangles. In an example, a vertical cross section of the busbar is a rectangle. In an example, the vertical cross section of the busbar comprises at least two different types of shapes, e.g., rectangles. In an example, the vertical cross section of the busbar comprises at least two types of shapes that are (e.g., substantially) the same, and that are distinct from eachAttorney Docket No. ENX-0159.WO other. The two types of shapes may comprise the same type of material or may each be from a different type of material. The two types of shapes may comprise the same class of material or may each be from a different class of material. Two of the shapes may be separated from each other by a gap. Two of the shapes may contact each other. A cross section of the busbar may comprise an indentation, e.g., a depression. The depression may be configured to accommodate (a) folded tab(s) (b) any tacky connector, (c) any welding, or (d) any combination thereof. The depression may be configured to increase adhesion of the tab to the (e.g., solid) busbar. The increased adhesion may be at least in part by increasing the (e.g., solid) busbar’s adhesion to (i) any tacky connector and / or (ii) any welding. A contacting surface of the busbar is an exposed surface of the busbar face(s) configured to contract the (a) the tab(s), (b) any tacky connector, (c) any welding, or (d) any combination thereof. The contacting surface may undergo surface treatment before the contact. The surface treatment may be configured to increase adhesion between the (e.g., solid) busbar and (a) the tab(s), (b) any tacky connector, (c) any welding, or (d) any combination thereof. The surface treatment may comprise roughening of the contacting surface. The surface treatment may comprise etching, scraping, or printing (e.g., 3D printing). The surface treatment may comprise mechanical treatment type, chemical treatment type, any plurality thereof, or any combination thereof. The (e.g., solid) busbar may comprise one or more perforations (e.g., holes). The perforation(s) may be configured to accommodate dimensionality changes occurring in the cell, e.g., during charging and / or discharging. The dimensionality changes of the cell may occur during its (e.g., normal) operation, testing, maintenance, storage, shipping, or any combination thereof.

[0097] In some embodiments, the cell undergoes pre-loading with charge carriers, e.g., before its regular use. The pre-loading may comprise loading the cell with charge carriers, e.g., “pre- lith iation” in the case of lithium cations being the charge carriers. The pre-loading (also referred herein as “buffering”) may be performed during manufacturing and / or before providing the battery for its intended use. The pre-loading may facilitate insertion of additional charge carriers for a charge carrier source such as a lithium source, into the electrode(s) of the battery such as into the anode(s). The electrode may be a vertically short electrode. The pre-loading may replenish (e.g., irreversible) loss of the charge carriers during formation of the battery, e.g., to increase (a) efficiency of the first cycle and / or (b) cell capacity. The pre-loading may result in a reservoir of the charge carriers within the cell, and / or smaller cycled voltage window. The pre-loading may improve current distribution, e.g., during fast charge. The pre-loading may improve the cycle life of the battery. Buffering or pre-loading may result in pressurization of the cell at its first charging cycle, e.g., due to loading of the anode with charge carriers such as lithium. The pressure adjuster described herein can aid in maintaining overpressure in the system without having to put pressure during buffering, e.g., the adjuster can establish a minimal / threshold overpressure in the device during formation without having to buffer the cell.Attorney Docket No. ENX-0159.WOA rough exposed surface of charge carrier plating may remain throughout the life of the battery, and may compromise function of the battery, e.g., due to depletion of charge carriers and / or due to causing a short (e.g., as a consequence of dendrite formation from an electrode to its counter electrode). In some examples, the geometry of a battery may include a side gap located adjacent to a cell, to enable electrolyte to flow into the gap during buffering.

[0098] In some embodiments, a cell comprises an electrode (e.g., reference electrode), a counter electrode, separated from each other by a gap, also referred to herein as “a separation space.” The separation space may comprise a separator, e.g., having a material comprising conduits or pores, e.g., micro conduits, or micropores. The pores and / or conduits may be configured to facilitate charge carriers (e.g., ions) to propagate through the separator. The conduits may be channels. Pores of the separator may form the conduit. The battery cell may comprise, or may be coupled with, an insulator such as a dynamic insulator. The battery cell may comprise, or may be coupled with, a dividing space. At least one component may be electrically insulating, e.g., the separator body, the insulator, or at least one component of the dividing space. The dividing space and the separating space may or may not have the same material content. A divider material may be disposed in the dividing space. The dividing material may or may not be of the same type of material as the separator. The separator may be (e.g., substantially) a plane, or a layer. The separator may be an ionically permeable microporous material suitable for use as a separator in an electrochemical cell. In some embodiments, the separator layer is coated with ceramic particles on one or both sides. In some embodiments, a cell includes an anode current collector in the center, which may comprise or be electrically coupled with, one of the electrode tabs on one of the sides of the secondary battery. In some implementations, the unit cell includes the anodically active material layer, the separator layer, the cathodically active material layer, and a cathode current collector in a stacked formation along a stacking axis. The cathode current collector may comprise a cathode tab devoid of cathode active material. The anode current collector may comprise an anode tab devoid of anode active material. The anode tab may be disposed at the same side of the cathode tab, or at a different side such as an opposing side.

[0099] In some embodiments, the cathode includes cathodically active material. The cathodically active material may include a cathodically active material including transition metal oxides, transition metal sulfides, transition metal nitrides, lithium-transition metal oxides, lithium-transition metal sulfides, lithium-transition metal nitrides, any plurality thereof, and / or any combination thereof. The cathodically active material may include transition metal elements of the transition metal oxides, transition metal sulfides, transition metal nitrides, any plurality thereof, and / or any combination thereof. The cathodically active material may include metal elements having a d-shell or f-shell. The cathodically active material may comprise metal element including Sc, Y, lanthanoids, actinoids, Ti, Zr, Hf, V, Nb, Ta, Cr, Mo, W, Mn, Tc, Re,Attorney Docket No. ENX-0159.WOFe, Ru, Os, Co, Rh, Ir, Ni, Pb, Pt, Cu, Ag, Au, any plurality thereof, and / or any combination thereof. The cathodically active material may include lithium cobalt oxide (LiCo02), LiNi05Mni 5O4, Li(NixCoyAlz)O2, lithium metal phosphate (e.g., lithium iron phosphate, LiFePOzi), Li2MnO , V2O5, molybdenum oxysulfides, phosphates, silicates, vanadates, sulfur, sulfur compounds, oxygen (air), lithium nickel manganese cobalt oxide (Li(NixMnyCoz)O2), any combinations thereof, and / or any plurality thereof. In some implementations, the cathode (e.g., cathodically active material) is selected from transition metal oxides, transition metal sulfides, transition metal nitrides, lithium-transition metal oxides, lithium-transition metal sulfides, transition-metal phosphates, lithium-transition-metal phosphates, and lithium-transition metal nitrides may be selectively used. The transition metal elements of these transition metal oxides, transition metal sulfides, and transition metal nitrides can include metal elements having a d- shell or f-shell. Specific examples of such metal element are Sc, Y, lanthanides, actinides, Ti, Zr, Hf, V, Nb, Ta, Cr, Mo, W, Mn, Tc, Re, Fe, Ru, Os, Co, Rh, Ir, Ni, Pb, Pt, Cu, Ag, and Au. Additional cathode active materials include LiCoO2, LiNio sM5O4, Li(NixCoyAlz)O2, LiFePO4, Li2MnO4, V2O5, molybdenum oxysulfides, phosphates, silicates, vanadates, sulfur, sulfur compounds, oxygen (air), Li(NixMnyCoz)02, and combinations thereof. The cathode active material may comprise, S (e.g., l_i2S in the lithiated state), LiF, Fe, Cu, Ni, FeF2, FeOdF32d, FeF3, COF3, COF2, CUF2, NiF2, where 0<d<0.5, metal oxides, metal sulfides, metal phosphates, binders, fillers, any plurality thereof, or any combination thereof. The filler may be inert to the chemistry of the device, e.g., chemistry of the cell. The binders may include polyvinylidene difluoride and / or polytetrafluoroethylene. The cathode may comprise LCO, NCM, LFP, LMO, Nickel, Lithium manganese Iron phosphate, lithium manganese iron phosphate, sodium-ion, nickel, manganese rich lithium, lithiated cobalt oxide, lithiated manganese oxide, lithiated nickel-manganese-cobalt oxide, any plurality of types thereof, or any combination thereof. The cathode (e.g., and the device) may be devoid of cobalt. The cathode active material may comprise a dopant. The dopant may comprise at least one type of elemental metal. The at least one type of elemental metal may comprise aluminum, a transition metal, a rare earth metal, any plurality of types thereof, or any combination thereof.

[0100] In some embodiments, the energy manipulation device may comprise a battery. The device may comprise Li-ion batteries, nickel metal hydride batteries, alkaline batteries, any plurality of types thereof, or any combination thereof. The battery may include a cell comprising Cu, Al, Ni, polyethylene, polypropylene, any derivatives thereof, any plurality of types thereof, or any combination thereof.

[0101] In some embodiments, the anode includes anodically active material. The anodically active material may include silicon (Si), germanium (Ge), tin (Sn), lead (Pb), antimony (Sb), bismuth (Bi), zinc (Zn), aluminum (Al), titanium (Ti), nickel (Ni), cobalt (Co), cadmium (Cd), any combination thereof, and / or any plurality thereof. The anodically active material may includeAttorney Docket No. ENX-0159.WO alloys and / or intermetallic compounds including Si, C, Ge, Sn, Pb, Sb, Bi, Zn, Al, Ti, Ni, Co, Cd, any combination thereof, and / or any plurality thereof. The anodically active material may include alloys, and / or intermetallic compounds. The anodically active material may include oxides, carbides, nitrides, sulfides, phosphides, selenides, tellurides of Si, Ge, Sn, Pb, Sb, Bi, Zn, Al, Ti, Fe, Ni, Co, V, or Cd, any combination thereof, or any plurality thereof. The anodically active material may include mixtures (e.g., containing Lithium), composites (e.g., containing Lithium), any combination thereof, and / or any plurality thereof. The anodically active material may include salts (e.g., of Sn), hydroxides (e.g., of Sn), lithium titanate, lithium manganate, lithium aluminate, lithium-containing titanium oxide, lithium transition metal oxide, ZnCo204, particles of graphite, particles of carbon, metal form of the charge carriers (e.g., lithium metal), any combinations thereof, and / or any plurality thereof. The anodically active material may be coated. The coating may comprise stabilized metal form of the charge carrier material (e.g., lithium metal particles). The particulate material may include lithium carbonate-stabilized lithium metal powder, lithium silicate stabilized lithium metal powder, other source of stabilized lithium metal powder or ink, any combination thereof, and / or any plurality thereof. The anode active material may comprise a material intercalating the charge carriers. The active material of the anode may include silicon and / or an allotrope of elemental carbon. The allotrope of elemental carbon may be any of the ones disclosed herein, e.g., active carbon, graphite, carbon fiber, carbon nanotube, amorphous carbon, and / or a fullerene. The tubular structures may comprise nested tubes, e.g., at least 2, or 3 nested tubes. The carbon fibers may be weaved, aligned (e.g., in parallel and / or at an angle relative to each other), randomly situated, or any combination thereof, as applicable. The anode may be a nearly (e.g., substantially) 100% silicon - carbon anode. The anode may comprise particulate material. The anode may comprise a carbon scaffold on which silicon is deposited (e.g., layer of silicon). An exposed surface of the silicon may be coated by the, or by at least one other, of the allotropes of elemental carbon. The carbon may comprise black carbon. The carbon may include hard carbon and / or soft carbon. The carbon-silicon structure may comprise successive layers and / or scaffold. The carbon may comprise a particulate material. The particulate material may serve as a base for deposition of the one or mor layers. The particulate material may or may not include crevices. The one or more layers may be deposited onto an exposed surface of the crevices. Anodically active materials may comprise carbon materials such as graphite and soft or hard carbons, or graphene (e.g., single-walled or multi-walled carbon nanotubes), or any of a range of metals, semi-metals, alloys, oxides, nitrides, compounds capable of intercalating lithium, compounds forming an alloy with lithium, any plurality thereof, or any combination thereof. Specific examples of the metals or semi-metals that may be used as the anode material include graphite, tin, lead, magnesium, aluminum, boron, gallium, silicon, Si-C composites, Si / graphite blends, silicon oxide (SiOx), porous Si, intermetallic Si alloys, indium,Attorney Docket No. ENX-0159.WO zirconium, germanium, bismuth, cadmium, antimony, silver, zinc, arsenic, hafnium, yttrium, lithium, sodium, graphite, carbon, lithium titanate, palladium, mixtures thereof, any plurality thereof, or any other combination thereof. In some implementations, the anodically active material may comprise aluminum, tin, silicon, an oxide thereof, a nitride thereof, a fluoride thereof, other alloy thereof, any plurality thereof, or any combination thereof. In some implementations, the anodically active material may comprise silicon, an alloy thereof, a composite thereof, an oxide thereof, any plurality thereof, or any combination thereof. In some embodiments, the battery may be without an active material (e.g., simple cell).

[0102] In some embodiments, the electrode has an excess of active material binding sites for the charge carriers than the counter-electrode, e.g., molar excess. The excess in binding sites can be at least about 5%, 10%, 15%, or 20%. The excess in binding sites can be at most about 50%, 40%, 30%, 20%, or 10%. The excess in binding sites between the electrode and the counter electrode can be between any of the aforementioned values, e.g., from about 5% to about 50%, from about 5% to about 20%, or from about 15% to about 50%. The electrode can be an anode and the counter electrode - a cathode.

[0103] In some embodiments, the active material is compressed to form a densified active material cake coupled with a current collector, e.g., as part of the electrode and / or counter electrode. The density of the active material coupled with the current collector, may be at least about 0.5 grams per centimeter squared (g / cc), 0.8 g / cc, 1 g / cc, 2 g / cc , 3 g / cc, 4 g / cc, 4.2 g / cc or 5 g / cc. The density of the active material coupled with the current collector, may be at most about 4.5 g / cc, 5 g / cc, 6 g / cc, or 8 g / cc. The density of the active material coupled with the current collector sheet, may be between any of the aforementioned values, e.g., from about 0.5 g / cc to about 8 g / cc, from about 0.5 g / cc to about 1 g / cc, or from about 2 g / cc to about 5 g / cc. In some embodiments, the density of the electrode active material is different from the density of the counter electrode active material, e.g., higher. The electrode can be a cathode, and the counter electrode an anode. In some embodiments, the density of the electrode active material is higher than the density of the counter electrode active material, e.g., by at least about 1 .5*, 2*, 3*, 4*, or 5*, with the symbol designating the mathematical operation of multiplication. High densities or high press densities refer to electrode coatings compacted by a calendaring operation to a density of at least 4gr / cc, or above. The densification may be accomplished by using a heavy roller, e.g., weighing at least about 1 ton (T), 2T, 3T, or 4T. The calendaring may be pressure controlled or height controlled, e.g., using a controls system such as disclosed herein. The calendering may be achieved, e.g., through a height-controlled operation. The height-controlled operation may set a fixed gap between the rollers, or between a roller and a surface, e.g., a gap of at most about 20 pm, 40 pm, 60 pm, 80 pm, or 100 pm, such as to define the active material thickness.Attorney Docket No. ENX-0159.WO

[0104] In some embodiments, the energy manipulation device comprises an electrochemical cell. The cell may comprise an electrode and a counter-electrode separated from each other by a gap. The device may comprise a simple cell, e.g., comprising passive electrodes. The simple cell may comprise anode current collector, cathode current collector separated from the anode current collector by a gap, an electrolyte, and charge carriers. The cell may comprise partially active electrodes - one current collector contacting an active material mass. The mass can be a layer. The cell may comprise fully active electrodes - both electrode and counterelectrode current collectors of the cell, each contacting a respective active material mass, e.g., a layer.

[0105] In some examples, the energy manipulation device may comprise a fuel cell. In other examples, the energy manipulation device may comprise a primary battery, which may be a non-rechargeable battery. The primary battery may be a battery comprising Li metal, alkaline, zinc-carbon, silver-oxide, and / or any other suitable material. In some examples, the energy manipulation device may comprise a secondary battery, which may be rechargeable. The secondary battery may be a battery comprising Li ion, lead acid (lead dioxide with sulfuric acid), nickel cadmium, nickel metal hydride, and / or any other suitable material. The use of a secondary battery or rechargeable battery may enable a reduction in environmental waste, as the materials may be reused for multiple cycles as compared to a primary or non-rechargeable battery. In some examples, the energy manipulation device described herein may comprise an electrochemical cell. As noted above, the cell may include an anode material and a cathode material. In an example, an electrochemical cell comprises passive electrodes, wherein the simple electrochemical cell includes an anode charge carrier, a cathode charge carrier separated from the anode by a gap, an electrolyte and charge carriers. In some examples, the energy manipulation device may comprise one or more active electrodes, wherein one charge carrier is in contact with an active material mass. The active material mass can comprise (e.g., be deposited in a form of) a layer. In some examples, the energy manipulation device may comprise one or more fully active electrodes, wherein the electrode and / or counter electrode charge carriers of a cell each contact a respective active material mass, e.g., a layer. The active material mass is configured to operatively coupled with its respective current collector of the electrode. The current collector may have an electrical conductivity of at least about 103Siemens / cm (S / cm), 104S / cm, 105S / cm, or 106S / cm. The current collector may have an electrical conductivity between any of the aforementioned values, e.g., from about 103S / cm to about 106S / cm, or from about 105S / cm to about 10sS / cm.

[0106] In some examples, the cell comprises an active material, a charge carrier, an electrolyte, any plurality of types thereof, or any combination thereof. The active material (e.g., mass such as layer) may be added to one side or to both sides of a cell or cell stack. In some embodiments, the electrode comprises a current collector (e.g., conductor) comprisingAttorney Docket No. ENX-0159.WO elemental metal, metal alloys, an allotrope of elemental carbon, any plurality of types thereof, or any combination thereof. The allotrope of elemental carbon may comprise graphite, carbon nanotubes, carbon wires, fullerenes, hard carbon, soft carbon, active carbon, carbon black, acetylene black, Ketjen black, cylindrical carbon nanotubes, carbon fibers, any plurality of types thereof, or any combination thereof. The nanotubes and / or nanowires, may be nested or nonnested. The cell may comprise charge carriers comprising salts such as lithium salts. The electrolyte material may comprise solid, semi-solid, liquid, any plurality of types thereof, or any combination thereof. The electrolyte materials may include salts, acids, and / or bases, e.g., dissolved in non-aqueous polar solvent(s). In some embodiments, the electrolyte may comprise a polymer-based electrolyte. The polymer-based electrolyte may include PEO-based polymer electrolyte, polymer-ceramic composite electrolyte, polymer-ceramic composite electrolyte, polymer-ceramic composite electrolyte, and / or similar such electrolytes. In some embodiments, the electrolyte may include an oxide-based electrolyte (e.g., lanthanum titanate (Lio.34Lao.56Ti03), Al-doped lithium lanthanum zirconate (Li6.24La3ZrzAlo.2401 1 .98), Ta- doped lithium lanthanum zirconate (Li6.4La3Zri.4Tao.6012), lithium aluminum titanium phosphate (Lit.4Alo.4Tit.6(P04)3), and / or similar such electrolytes. In some embodiments, the electrolyte may comprise a solid electrolyte (e.g., sulfide-based electrolyte such as lithium tin phosphorus sulfide (LiioSnP2Si2), lithium phosphorus sulfide (13-U3PS4), lithium phosphorus sulfur chloride iodide (Li6PS5C1o.91o.i), and / or similar such electrolytes. The electrolyte may comprise ethylene carbonate, diethylcarbonate, dimethylcarbonate, ethylmethylcarbonate, propylene carbonate, any derivatives thereof, or any combination thereof.

[0107] Fig. 1 shows in example 100 a schematic representation of a cell, the cell comprising an electrode 102a - “C” (e.g., a cathode), and an opposing electrode which is a counter electrode 105a - “A" (e.g., an anode). A separator is disposed in separator space (e.g., gap) 103 - “B.” The battery cell is disposed in a battery having housing 109. The housing can be rigid, or flexible. The housing may include a rigid portion and / or a flexible portion. The battery can optionally have an insulator 104. The insulator may comprise one or more materials comprising a ceramic, a polymer, or a resin. The battery may comprise one or more insulator types. In an example, a polymer may fill a cathode gap, and alumina fills a cathode gap, the gap being from the edge of the cell to its immediately adjacent edge of the case (also herein “casing”). In some embodiments, insulator may comprise a non-electrically conductive material. The ceramic may comprise alumina (AI2O3), zirconia (ZnO2), magnesium oxide (MgO), boron nitride (BN), mullite, boehmite, or silicon carbide (Si-C, e.g., in pure form). Under normal conditions during use of the battery, the main current is a load current 106 passing from one electrode to its opposing electrode, and through separation space 103. When volume 104 comprises the insulator, the insulator contacts at least at opposing sides 102b and 102c of electrode 102a and at opposing sides 105b and 105c of counter-electrode 105a.Attorney Docket No. ENX-0159.WO

[0108] Fig. 1 shows in example 110 a schematic representation of a cell, the cell comprising an electrode 112 - “C” (e.g., a cathode), and an opposing electrode which is a counter electrode 115 - “A” (e.g., an anode). A separator is disposed in separator space 1 13 - “B.” The battery cell is disposed in a battery having housing 119. The separation space extends 121 beyond electrode 112, and extends 122 beyond counter electrode 1 15, the extension being along a long axis of each of the electrode, the long axis depicted in Fig. 1. The extension can extend longer in the lateral direction. The extension can form the tab. The battery has an insulator 114. Under the normal conditions, the load current 116 may be passing through separation space 113.

[0109] In some embodiments, the different extension distances of the components of the cell in the lateral direction, form a corrugated (e.g., misaligned) face of the cell, and thus a set of the cells, e.g., as depicted in Fig. 1 , 120 for a cell. The cell can comprise at least one uneven side, e.g., as is depicted in Fig. 1 , 120. The uneven (e.g., misaligned) side can create a wavy side of a set of cells.

[0110] Fig. 2 shows a schematic example 200 of a current collector in the form of a film or strip. The electrode active material may contact (e.g., be deposited onto) a conductive sheet, e.g., having a thickness of at most about 6 millimeters (mm), 5mm, 2.5mm, 1 mm, or 0.5mm. The conductive sheet may be a foil, e.g., having a thickness of at most about 0.4mm, 0.2 mm, or 0.1 mm. The current collector may comprise an internal portion, e.g., when assembled in the battery. The internal portion of the current collector contacts the active material of the electrode. The tab may be (e.g., substantially) devoid of the electrode active material. The current collector has a length axis and a width, and a height. The current collector has a face type having a largest surface area, the face type including sections 201 , and 202. The current collector has a length 203, a width 204, and a height 205. Section 202 designates the tab of the current collector that can bend upon assembly of the energy manipulation device such as to couple with a busbar, and section 201 designates the planar section of the current collector that can couple to an electrode active material, e.g., a powder with binder(s) and / or filler(s). In the example shown in 200, the tabs assume the same width 204 along their length. In some embodiments, the tabs contract (e.g., narrow such as taper) along their length, e.g., and along the longest axis 211 . Longest axis 21 1 of the current collector intersects position 214 on a face of the electrode having height 205 and width 204, which face has the smallest surface area in the example of 200. The current collector has a shorter axis 212 normal to axis 21 1. The contraction of the tabs along axis 211 may be symmetrical about axis 211 , e.g., using a mirror symmetry, the mirror being along axis 21 1 .[01 1 1] In some embodiments, the current collector may be an anode current collector. In some embodiments, the current collector may be a cathode current collector. The anode current collector may comprise a conductive material such as copper, carbon, nickel, stainless-steel,Attorney Docket No. ENX-0159.WO cobalt, titanium, and tungsten, and alloys thereof, or any other material suitable as an anode current collector layer. The current collector has an electrical conductivity of at least about 103 Siemens / cm, 104 Siemens / cm, or 105 Siemens / cm. The current collector has an electrical conductivity between any of the aforementioned values, e.g., from about 103 Siemens / cm to about 105 Siemens / cm. The cathode current collector may comprise aluminum, nickel, cobalt, titanium, and tungsten, or alloys thereof, or any other material suitable for use as a cathode current collector layer. In some embodiments, the cathode current collector comprises a metal such as aluminum, carbon, chromium, gold, nickel, NiP, palladium, platinum, rhodium, ruthenium, an alloy of silicon and nickel, titanium, or any combination thereof. In an example, a cathode current collector comprises gold or an alloy thereof such as gold silicide. By way of further example, in one embodiment, a cathode current collector comprises nickel or an alloy thereof such as nickel silicide.

[0112] Fig. 2 shows in example 250, a schematic vertical cross section of various batteries, showing arrangement and / or folding of battery cells with respect to a Cartesian coordinate system. In example 251 , battery cells are arranged parallel to each other. Examples 252-255 show various folding of a sheet comprising one or more battery cells, with 252 showing a zigzag fold, 253 showing a top hat fold, 254 showing a sinusoidal type fold, 255 showing a spiral (e.g., rolling) fold, and 256 an oval or oblong spiral (e.g., rolling) fold. The battery may comprise a battery cell folded in a wound (e.g., jelly roll) configuration having an oblong or cylindrical configuration, e.g., as shown in Fig. 7, 750.

[0113] In some embodiments, one or more cells are disposed within a housing to form the device, e.g., battery. The housing may insulate the battery from one or more reactive agents (also referred to herein as “reactive species”) in the ambient environment external to the device. The reactive agent(s) may comprise oxygen, water, alcohol, thiol, sulfuric acid, phosphoric acid, carboxylic acid, hydrogen sulfide, any plurality thereof, or any combination thereof. The reactive agent(s) may be oxygen based, sulfur based, and / or phosphorous based. The reactive agent(s) may include water and / or oxygen. In an example, the reactive agent(s) comprise water in a liquid and / or vapor form. The water may be in the form of droplets. The housing may be configured to separate and / or insulate the cell(s) from the reactive agent(s) present in the ambient environment external to the device, e.g., to curtail (e.g., hinder, or prevent) reactive agent(s) from reaching the cell such as including reaching the electrode(s) and any fuse of the device.

[0114] The energy manipulation device is of a (e.g., Euclidean) three-dimensional (3D) geometric shape. The device with the (e.g., Euclidean) 3D geometric shape may comprise the cell assembly, the constraint system (e.g., the rigid constraint), the battery enclosure (e.g., the pouch), or any combination thereof, as described herein. The device may have an asymmetrical shape, e.g., its housing may be asymmetrical in shape. The Euclidean 3D shapeAttorney Docket No. ENX-0159.WO may comprise a cylinder or a prism. The prism may be a Euclidean prism, or an amorphous prism. In some embodiments, the battery is a prismatic battery. In some embodiments, the battery is a cylindrical battery. The battery may have a first FLS such as a height (e.g., Fig. 3, 331) of at least about 1 millimeters (mm), 2 mm, 3 mm, 3.5 mm, 4.8 mm, 5 mm, 5.4 mm, 5.5 mm, 6 mm, 8 mm, or 10 mm. The first FLS of the battery may be of any value between any of the aforementioned values, e.g., from about 1 mm to about 10 mm. The first FLS (e.g., height) may be the height of the cell assembly, a constraint system, a battery enclosure, or any combination thereof. The battery may have a second FLS such as a length (e.g., Fig. 3, 332) of at least about at least about 10 millimeters (mm), 29 mm, 37 mm, 50 mm, 71 mm, 80 mm, 100 mm, 150 mm, or 200 mm. The second FLS of the battery may be of any value between any of the aforementioned values, e.g., from about 10 mm to about 200 mm. The second FLS (e.g., length) may be the length of the cell assembly, a constraint system, a battery enclosure, or any combination thereof. The battery may have an aspect ratio of the second FLS to the first FLS of at least about 5:1 , 8:1 , 10:1 , 15:1 , 20:1 , 25:1 , 35:1 , or 50:1. The ratio of the second FLS to the first FLS may be the ratio between the length of the cell assembly, a constraint system, a battery enclosure, or any combination thereof, to the height of the cell assembly, a constraint system, a battery enclosure, or any combination thereof. The battery may have an aspect ratio of the second FLS to the first FLS between any of the aforementioned values, e.g., from about 5: 1 to about 50:1. The battery may have an aspect ratio of the second FLS to the third FLS of at least about 5:1 , 4:1 , 3:1 , 2:1 , or 1 :1. The battery may have an aspect ratio of the second FLS to the third FLS of at most about 1 : 1 , 1 :2, 1 :3, 1 :4, 1 :5, 1 : 10, 1 :20, or 1 :30. The battery may have an aspect ratio of the second FLS to the third FLS between any of the aforementioned values, e.g., from about 5:1 to about 1 :50. The ratio of the second FLS to the third FLS may be the ratio between the length of the cell assembly, a constraint system, a battery enclosure, or any combination thereof, to the width of the cell assembly, a constraint system, a battery enclosure, or any combination thereof.

[0115] Fig. 3 shows schematic perspective view examples of energy manipulation devices such as batteries and battery cell architectures therein, relative to a Cartesian coordinate system. Example 300 shows a cylindrical battery housing having a length 302 and height 301 , which is a diameter. The battery may comprise cell(s) that form a rolled sheet. In example 300, each of the bottom and top faces of the cylinder has a smaller surface area as compared to the side surface of the cylinder - to the curved surface of the cylinder. Example 330 shows a prismatic battery housing that is a rectangular prism, or a cuboid. The battery has length 332, height 331 , and width 333. Battery cells 335 are stacked in the battery along height 331 , and along the Z direction. In example 330, face XY has a larger surface area than face XZ, and face XY has a larger surface area than face YZ. Example 350 shows a prismatic battery housing that is a rectangular prism, or a cuboid. The battery has length 352, height 351 , andAttorney Docket No. ENX-0159.WO width 353. Battery cells 335 are stacked in the battery along length 352, and along the X direction. In example 350, face XY has a larger surface area than face XZ, and face XY has a larger surface area than face YZ.

[0116] In some embodiments, the device such as battery comprises battery cells. The battery cells may be stacked along an axis. A dividing space may be disposed between every two immediately adjacent cells such that a first cell contacts the first face of the dividing space, and a second cell contacts a second face of the dividing space opposing its first space. The dividing space may comprise an insulator, e.g., any insulator disclosed herein. The insulator may or may not comprise the dynamic insulator. The dividing space may be configured to electrically separate one cell from another. The stack of cells may follow a pattern, the pattern may comprise a sequence. The sequence may comprise an arrangement of components of the battery cell with respect to each other. The sequence may comprise an anode, a separation space, a cathode, and a dividing space. The sequence may follow a CBAS pattern, or a CBASABCS pattern, with “C” designating a cathode, “B” designating a separation space, “A” designating an anode, “S" designating the dividing space, and “E” designates an end plate, e.g., see Fig. 4. The cells may be stacked in one or more groups. The separation space may comprise two opposing faces. A face of the separation space contacting the anode, and an opposing face contacting the cathode. The cell may comprise components comprising an anode, a cathode, a separation space, and an optional dividing space. The dividing space may comprise the same type of material as the separation space. The dividing space and the separation space may be (e.g., substantially) the same. The components of the cell may be disposed along an axis. The components of the cell may be (e.g., substantially) symmetrically arranged along the axis, e.g., in mirror symmetry, the mirror plane running along the axis, and / or in a rotational symmetry, the rotational axis running along the cell stacking axis (e.g., parallel to axis 490 in Fig. 4). At least two components of the cell may extend in a direction (e.g., substantially) perpendicular to the cell stacking axis at a (e.g., substantially) same distance. At least two components of the cell may extend in a direction (e.g., substantially) perpendicular to the cell stacking axis (e.g., laterally) at a different distance from that axis. The different distance extension of the components can form a corrugated (e.g., misaligned) face of the cell, and of the set of cells, e.g., as depicted in Fig. 1 , 120. See also sides (e.g., edges) of cell sets in Fig. 4, 400, and 450. In an example, the cathode extends less than the anode, the extension being in a direction perpendicular to the cell stacking axis. In an example, the separation space extends more than the anode and / or more than the cathode, the extension being in a direction perpendicular to the cell stacking axis. The endplate and the rigid constraint portion may be of the same material type or of different material types. For example, the endplate and the rigid constraint portion may comprise stainless steel. For example, the rigid constraint portion may comprise stainless steel (e.g., SS-301 or SS-316), and the endplatesAttorney Docket No. ENX-0159.WO may comprise aluminum. The rigid constraint portion may comprise stainless steel, or Inconel. Any portion of the constraint system (e.g., the rigid constraint portion) may comprise a coating, e.g., a lacquer. The coating may comprise ClearClad, polyimide, or an electrodeposition coating. The electrodeposition coating may comprise Shimizu type coating. The coating may hinder deposition of charge carrier plating such as lithium plating, e.g., during use of the cell assembly.

[0117] Fig. 4 shows a schematic cross-sectional example 400 of a battery comprising cathode 402, anode 405, separation space 403, and dividing space 407. The battery cells are disposed in volume 404 of the battery that can include an insulator such as a dynamic insulator. The battery cells are stacked along an axis 490, in a repeating CBAS arrangement. Each anode “A” in the battery includes an anode current collector such as 413, the anode current collectors being coupled in parallel to a main anode current collector 414 - an anode busbar, ending with anode contact 41 1 forming a terminal tab. Each cathode “C” in the battery includes a cathode current collector such as 416, the cathode current collectors being coupled in parallel to a main cathode current collector 417 - cathode busbar, ending with cathode contact 412 - terminal cathode tab.

[0118] Fig. 4 shows a schematic cross-sectional example 450 of a battery comprising cathode 452, anode 455, separation space 453, and dividing space 457. The battery cells are disposed in volume 454 of the battery that can include an insulator such as a dynamic insulator. The battery cells are stacked along an axis 490, in a repeating CBASABCS arrangement. Each anode ‘A” in the battery includes a current collector such as 463, the anode current collectors being coupled in parallel to a main anode current collector 464 (e.g., busbar), ending with anode contact 461 - anode terminal tab. Each cathode “C” in the battery is operatively coupled (e.g., connected) with a cathode current collector such as 466, the cathode current collectors being coupled in parallel to a main cathode current collector 467 (e.g., busbar), ending with cathode contact 462 -cathode terminal tab. In Fig. 4, the main cathode current collector is disposed on a different face of the set of cells as the main anode current collector, which is the opposing face.

[0119] In some embodiments, the battery comprises one or more main current collectors, e.g., as disclosed herein. The main current collector may include a busbar and / or a busbar extender. The main current collectors may or may not contact the insulator covering the edges of the cells. In the example shown in Fig. 4, 400, the main current collectors 417 and 414, are separated from the insulator 404 by a gap. In the example shown in 400, the main current collectors 417 and 414 contact the insulator 404.

[0120] In some embodiments, an end plate is disposed at a distal end of a cell set, e.g., at opposing distal ends of the set of cells and along the cell’s stacking axis (e.g., Fig. 4, 490). Fig. 4, 400 shows an example of two opposing end plates disposed at both distal ends of a set ofAttorney Docket No. ENX-0159.WO stacked cells, the end plates designed by “E,” the end plate 420 contacting the insulator at its opposing lateral ends. Fig. 4, 450 shows an example of two opposing end plates disposed at both distal ends of a set of stacked cells, the end plates designed by “E,” the end plate is devoid of the insulator at its two opposing lateral ends - normal to stacking axis 490.

[0121] In some embodiments, the device is of a (e.g., Euclidean) three-dimensional (3D) geometric shape In some embodiments, an energy manipulation (e.g., storage) device such as a battery, comprises a plurality of cells. Each of the cells comprises an anode separated by a gap from a cathode. The gap may comprise a separator. The cell may comprise one or more electrolyte types. Each of the electrodes (e.g., anode and cathode) comprises a current collector, e.g., a strip, a foil, or a film, of conductive material on which the active electrode material is disposed of. The conductive material may comprise an elemental metal, a metal alloy, or an allotrope of elemental carbon. In an example, the elemental metal comprises aluminum or copper. In an example, the metal alloy may comprise stainless steel. In an example, the allotrope of elemental carbon may comprise carbon nanotubes, or carbon fibers. The tubular structures (e.g., nanotubes) may comprise nestled tubes, e.g., at least about 2, 3, 4, or more nestled tubes. The carbon fibers may be weaved, randomly dispersed, or any combination thereof. The strip of conductive material may or may not comprise a composite material. At least two cells in the energy manipulation device (e.g., battery) may be stacked in a direction (e.g., substantially) normal to their face having the largest surface area. The electrode has an electrode face having the largest surface area, and the counter-electrode has a counter-electrode face having the largest surface area. In some embodiments, there is a difference in a volume of the cell between a state of charge and a state of discharge of an electrode of the cell. The volume of the cell may repeatedly and / or reversibly alter between the state of charge and the state of discharge repeatedly. The reversible discharge may not be completely reversible, e.g., there may be an attrition in the properties of one or more components of the cell during a cycle of charge / discharge. The repeated cycling between the state of charge / discharge may comprise at least about 150 cycles, 200 cycles, 250 cycles, 300 cycles, 400 cycles, 500 cycles, 700 cycles, 800 cycles, 1000 cycles, 1200 cycles, or 1500 cycles. The repeated cycling between the state of charge / discharge may comprise any value of cycle between any of the aforementioned cycles, e.g., from about 150 cycles to about 1500 cycles. In some embodiments, there is a difference in a volume of the cell between a state of charge and a state of discharge of an electrode of the cell. The change in volume may comprise a change in at most about 20*, 25*, 50*, 100*, 200*, 300*, or 400* of an initial volume of the cell. The change in volume may comprise a change in at least about 10*, 25*, 50*, 100*, 200*, or 300* of an initial volume of the cell. The change in volume may comprise a change in any of the aforementioned values, e.g., from about 10* to about 400*, from about 100* to about 400*,Attorney Docket No. ENX-0159.WO or from about 20* to about 200*. The symbol “*” designates the mathematic operation of multiplication.

[0122] The energy manipulation device may comprise at least one constraint (e.g., a brace, or a harness). The constraint may be configured to (e.g., substantially) maintain constant dimensions and / or volume of the device during the charge / discharge operations. The constraint may be configured to maintain internal pressure in the device, e.g., during the charge / discharge operations. The internal overpressure in the device may be at most about 100PSI, 150PSI, 200PSI, 500PSI, 1000 PSI, 2000 PSI, 3000 PSI, 5000PSI, or 10000PSI. The internal overpressure in the device may be at most about 50 PSI, 100PSI, 150PSI, 200PSI, 500PSI, 1000 PSI, 2000 PSI, 3000 PSI, or 5000PSI. The internal overpressure in the device may be between the above referenced pressures, e.g., from about 50PSI to about 10000 PSI, from about 50PSI to about 500PSI, or from about 50PSI to about 2000PSI, or from about 100PSI to about 3000PSI. The internal overpressure in the device may be greater than the ambient pressure external to the device, e.g., above 14.6 PSI. In some embodiments, the energy manipulation device has a face type having the largest surface area among its face types. The face a face type having the largest surface area may deform (e.g., bend) during the, or as a consequence of, the overpressure phase. The face type having the largest surface area may (e.g, substantially) reversibly deform during the life of the device. Substantial reversal of the face’s deformation may be within the specification and / or intended use of the device.

[0123] In some embodiments, the battery cell set is disposed in an orthogonal stacked configuration.

[0124] In some embodiments, the device comprises a constraint system. The constraint system may be applied over one or both of the X-Y surfaces of the device (e.g., battery). In some embodiments, the constraint system includes a plurality of perforations to facilitate distribution (e.g., by flow of) an electrolyte solution after the cell, or cell set, has been assembled. In some embodiments, the casing comprises stainless steel, aluminum, titanium, beryllium, beryllium copper (hard), copper (O2free, and / or hard), nickel, other metals or metal alloys, composite, polymer, ceramic, any plurality thereof, any combination thereof, or any other suitable material as applicable.

[0125] In some embodiments, the constraint system comprises (i) one or more endplates, (ii) one or more rigid constraint portions, (iii) an optional coating, (iv) an adhesive layer, or (v) any combination thereof. The optional coating may comprise an insulator. The optional coating may be configured to deter deposition of a reduced form of the charge carriers, e.g., may be configured to deter lithium plating on the constraint portion in which the coating is deposited. The constraint system may comprise any subset, or any combination, of the aforementioned components, e.g., depending at least in part on a design configuration of the cell assembly, operation conditions, and / or chemical makeup of the cell assembly such as of its activeAttorney Docket No. ENX-0159.WO material. As used herein, the term “constraint system” refers to a structural assembly comprising one or more rigid constraint portions, one or more endplates, an optional insulating coating and / or adhesive layer. The term “constraint body” refers to the rigid portion of the constraint system comprising a planar middle section and two opposing flanges. The rigid portion and flanges of the constraint body can be made from a single unit of material, e.g., a bent sheet such as of metal.

[0126] In some embodiments, the constraint system is adapted to withstand pressure variation generated during cycling of the cell assembly. The pressure variation may include an overpressure as compared to the ambient environment external to the device such as battery. The pressure may be applied along a lateral direction of the constraint system, defined as perpendicular to a stacking axis of the cell assembly (e.g., Y-direction in Figs. 5 and 6). The constraint system may maintain structural integrity under pressure variation of at least about 450 pounds per square inch (psi), 500psi, 600 psi, 700 psi, or 800 psi. The pressure variation may be at most about 900 psi, 1000 psi, 1100 psi, or 1200 psi. The pressure variation may be of any value between the aforementioned values, e.g., from about 500 psi to about 1200 psi, for example while minimizing permanent deformation of the constraint structure. The pressure variation may be measured along the lateral axis (e.g., X axis in figs. 5 and 6). The pressure variation may be measured relative to the pressure of the ambient environment (about 14.7 psi). The maximal pressure in the cell may differ based on the anode active material and the charge carriers used. For the case of lithium ions, Si-C may exert about half the pressure exerted by SiOx, e.g., Si-C may exert about 450 PSI in a configuration, and SiOx about 1200 PSI in an otherwise similar configuration.

[0127] In some embodiments, the constraint system is adapted to maintain dimensional stability of the cell assembly during volumetric change. The volumetric change may be associated with charge and discharge cycles of the cell assembly. The volumetric change undergone by the cell assembly constrained by the constraint system, may be at most about 2%, 3%, 5%, 8%, 10%, 12%, or 14%. The volumetric change may be of any value between the aforementioned values, e.g., from about 2% to about 14%, or from about 2% to about 10%. The volumetric change may be in accordance with applicable jurisdictional standards and / or industry standards. The standards may include dimensional change limits and / or mechanical strain thresholds defined by product safety or certification standards, e.g., UN 38.3, IEC 62133, UL 2580, or analogous regional standards.

[0128] Fig. 5 shows in example 500 an exploded view of a pair of constraints 501a and 501 b encasing a set (e.g., a population) of stacked battery cells 502, the pair of constraints being part of a constraint system. Example 550 shows an exploded view in which the two constraints 501 a-b are closer to the stacked cell set 502. Fig. 5 is shown with respect to a Cartesian coordinate system. Each of the constraints may curb expansion of the battery cells duringAttorney Docket No. ENX-0159.WO charge and / or discharge. Curbing the expansion may or may not be anisotropic. In the example shown in Fig. 5, the constraint can deter expansion of the cells anisotropically along the Y axis.

[0129] In some embodiments, the cell comprises an anode separated by a gap from an anode. The cell may comprise a separator disposed in the gap. The cells may be elongated, e.g., an elongated box. The face of the cell opposing the largest surface area face of the electrode (e.g., anode or cathode) may have an aspect ratio of at least about 10:1 , 15:1 , 20:1 , 35:1 , or 50:1 , the aspect ratio being a length (e.g., Fig. 6, 631) of the face to a height (e.g., Fig. 6, 632) of that face. The cell may have an aspect ratio between any of the aforementioned values, e.g., from about 10:1 to about 50:1 , the aspect ratio being the length of the cell to the height. The cell may have an aspect ratio of at least about 5: 1 , 8:1 , 10:1 , 15:1 , 20:1 , 25:1 35:1 , or 50:1 , the aspect ratio being a height (e.g., Fig. 6, 632) of the cell to a width (e.g., Fig. 6, 604, showing a width of three cells). The cell may have an aspect ratio between any of the aforementioned values, e.g., from about 5:1 to about 50:1 , the aspect ratio being the height of the cell to the width.

[0130] Fig. 6 shows in example 600 a lateral portion of three cells, each comprising an electrode such as 601 , a counter electrode such as 603, and a separator 602 disposed between each immediately adjacent pair of electrode and counter electrode. In example 600, the electrode (e.g., 601) extends less than the counter electrode 603 to the lateral edge 604 of the stacked cells, with the separator extending more towards the edge than the electrode, and then the counter-electrode, e.g., thus forming a corrugated, or wavy, lateral edge 604. Example 630 shows a stack of cells, e.g., in which the cells are horizontally stacked. The stacking axis of the cells may be parallel to a face of the cell having the largest surface area, e.g., of a prismatic battery such as a rectangular box.

[0131] Example 650 shows a set of stacked cells 651 enclosed by two opposing casings 652a and 652b. Current collectors of the stacked cells are coupled with connectors 653a and 653b. 653a connect to the electrodes of the set of cells, and 653b connects to the counter-electrodes ofthe set of cells. The cells enclosed by the casings (e.g., housing or case), are further secured by a flexible material 655, e.g., a band. The flexible material may comprise a polymer or a resin. The flexible material may be an electrical insulator. The casing may comprise one or more openings. In the example of Fig. 6, casing 652a includes oblong openings, e.g., that are evenly spaced along the X direction. Fig. 6 is shown with respect to a Cartesian coordinate system.

[0132] Fig. 7 shows in example 700 an exploded view of a pair of constraints 701a and 701 b of a constraint system encasing a set (e.g., a population) of stacked battery cells 702. Each of constraints 701 a-b includes oblong openings, e.g., that are evenly spaced along the X direction. Fig. 7 is shown with respect to a Cartesian coordinate system. The constraint may form a cage, e.g., having one or more openings such as slits, e.g., oblong silts or holes.Attorney Docket No. ENX-0159.WO

[0133] In some embodiments, the cell is configured with at least one gap portion that can be occupied during expansion of the active material. The gap may be between the electrode and counter electrode, or adjacent to an edge (e.g., side) of the electrode. Some of the cells described herein comprise gaps located adjacent to the electrode(s), e.g., at side(s) of the electrode(s). These gaps may enable electrolyte to flow into the gaps, e.g., during buffering. Accordingly, when the starting material is added to the device (whether in an active or inactive state), the starting material can occupy these gaps.

[0134] Example 730b is a microscope image of section 730a. The image shows a set of cells comprising (a) anodes including (i) anode active material such as 731 and (ii) anode current collector such as anode current collector 732; (b) anodes including (iii) anode active material such as 733 and (iv) cathode current collector such as cathode current collector 734; (c) separators such as separators 735 and 736; and (d) insulating material such as 737. The insulating material 737 is disposed in a side gap at the edge of the electrode. Each cathode is separated from its immediately adjacent anode by a gap, the separator disposed in the gap. In the example shown in 730, a pair of immediately adjacent separators are separated from each other. The separators extend more toward an edge of the set of cells, as compared to the cathode, which extends more towards the edge than the anode. The insulator is disposed in the volume between the set of cells and the edge of the set of cells. The ends of the separators along the z direction alternate between a first pair of immediately adjacent separator ends pointing towards each other, and a second pair of immediately adjacent separator ends pointing away from each other, the ends being along the z direction. For example, the ends of separators 735 and 736 point towards each other. Each anode and cathode in the cell interlace each other along the y direction (e.g., are disposed alternatively), which is the stacking direction of the cells. In the example shown in 730b, (a) the active anode material is disposed at both sides of the respective anode current collector and (b) the active cathode material is, disposed at both sides of the respective cathode current collector, the sides being along the z direction. In the example shown in 730b, (a) the active anode material is disposed on both side of the anode current collector such that it (e.g., substantially, schematically and / or generally) forms a mirroring plane for the anode active material, and (b) the active cathode material is disposed on both side of the cathode current collector such that it (e.g., substantially, schematically and / or generally) forms a mirroring plane for the anode active material.

[0135] In some embodiments, the interior of the casing is separated from an exterior of the casing, e.g., to hinder reactive specie(s) in the external environment to traverse to the interior environment such as to cause the harm. Terminals configured to conduct the electrical current flow are configured to allow electrical connectivity of the external environment with the cell(s) disposed in the interior of the housing. The housing comprises a seal to separate the interior environment of the housing from its exterior environment. The terminals extend through theAttorney Docket No. ENX-0159.WO seal from the interior of the housing (e.g., enclosure such as a pouch) to the external environment. Each of the terminals can be coupled with the housing (e.g., at the seal area) by coupler. The coupler may comprise a compressible material such as a malleable material. The terminal may be secured to the housing by an adhesive, e.g., at the seal. The terminal may be secured to the seal at least in part by the adhesive and / or by the compressible material. The compressible material may be an adhesive. The compressible material and / or the adhesive, may comprise a polymer, a resin, any combination thereof, or a plurality of types thereof. The adhesive may be (e.g., substantially) confined to the seal. The adhesive may comprise polypropylene or epoxy glue. The fuse may be reinforced by an adhesive, e.g., to any portion of the device such as disclosed herein. The fuse may be located (e.g., and reinforced to) a portion of the device sufficiently distant from susceptible material(s) such that when the fuse activates, the harm will not be made due to activation of the susceptible material(s). The susceptible material may participate in the chemistry of the device, e.g., of the cell. The susceptible material(s) may comprise any of the active materials of the cell, any electrolyte, any separator, any insulator, any divider, any current collector, any busbar, any adhesive, any plurality (e.g., of types or otherwise) thereof, or any combination thereof. The compressible material may be disposed in the seal, in an interior of the housing, in the exterior of the housing, or any combination thereof. In some embodiments, the terminal is compressed by the compressible material, which is compressed by the seal of the housing.

[0136] In some examples, the battery is disposed in a housing (e.g., enclosure) comprising a pouch. The pouch may insulate the battery content (e.g., the cell therein) from one or more reactive agent in the ambient environment external to the pouch. The pouch may enclosure the case of the battery, and the cell(s) housed therein. The pouch may comprise one or more layers. The one or more layers may include a material comprising a polymer, a resin, an elemental metal (e.g., strip, film, foil, and / or powder thereof), or a metal alloy (e.g., strip, film, foil, and / or powder thereof). The one or more layers may include one or more of these materials. The pouch may have an external surface having a color comprising black, silver, or white. In an example, the pouch is rigid, e.g., the pouch may constitute a can.

[0137] Fig. 7 shows an example of vertical cross sections of various batteries with respect to a Cartesian coordinate system, viewed from a side having a length and a height (e.g., Fig. 3, height 351 and length 352), and depicted as a cross section. Example 700 shows battery cells such as cell 702 stacked in a direction normal to the z axis, the battery having housing 701. During a charge and discharge cycle, the battery expands and contracts. The expansion creates a force in the battery in a direction perpendicular to the stacking direction of the cells and toward the edges of the battery (e.g., along arrows 703), and in a direction along the stacking axis such as along 704. Constraints 707a and 707b are coupled with the cell stack to curb expansion. The constraints may limit displacement along the direction of arrows 703 andAttorney Docket No. ENX-0159.WO along 704. The constrain may anisotropically constraint expansion of the cell stack. The constraints 707a-707b are disposed opposing each other and separated by a gap. Endplates 706a and 706b are disposed between the constraint and the cell stack. Each endplate may contact a distal end of the cell stack along the stacking direction. The endplates and the constraints may be arranged in a mirror symmetry about the stacking axis. The contraction and expansion may cause pressure buildup inside the battery. Heat may be generated during charge and discharge cycles, e.g., in interior of the cell stack such as along 704. The heat may be dissipated from the battery along arrows 703, increasing operational safety by reducing the risk of thermal runaway. Charge carriers generated from a precursor card may diffuse into the cell stack in the direction of arrow 705 (e.g., from locations corresponding to arrows 703). Diffusion of charge carriers may occur through perforations in the constraint system (e.g., perforation 651 of Fig. 6).

[0138] In some embodiments, one or more cells are enclosed in a rigid enclosure. The rigid enclosure may comprise the constraint system and / or endplates. The enclosure may comprise an elemental metal, a metal alloy, an allotrope of elemental carbon, a polymer, a resin, a plurality of types thereof, or any combination thereof. The housing may be made of a material with greater, lesser, or (e.g., substantially) equal hardness compared to the enclosure. In an example, the housing may comprise a pouch having a lower hardness than a rigid enclosure such as a can. The pouch may be nested inside a harder housing (e.g., a can). A protective layer may be disposed between the enclosure and the housing, e.g., fig. 6, 635. The protective layer may comprise an elastic material, a polymer, a resin, a plurality of types thereof, or any combination thereof. The protective layer may form a band around the sides of the enclosure. The sides may include types with relatively smaller surface area. The protective layer may have a thickness, elasticity, and / or durability sufficient to cushion physical interaction between the housing and the enclosure. The protective layer may have a sponge-like geometry. The layer may be porous or non-porous. The protective layer may include polyurethane, polypropylene, polyethylene, and / or rubber. The layer may be attached to the enclosure by adhesion or by compression. The protective layer may be a pouch protective layer (PPL).

[0139] In an example, charge carriers and / or an electrolyte mixture are introduced into one or more cells from outside the cell assembly and within the housing. The entering materials may enter from outside the constraint system, outside the endplates, and / or from within the housing (e.g., pouch and / or can). Entry may occurfrom a seal, a surface of the housing, or a protective cell layer. Entry may occur by diffusion along a concentration gradient. When the starting material enters from a side of the battery having the largest surface area (e.g., top or bottom surface in example 650 of Fig. 6), diffusion may proceed inward toward the stack interior (e.g., towards 704 and opposing the directions of arrows 703 in Fig. 7). Entry may be faster when the stack includes elongated cell components with a high aspect ratio of height (e.g., 351) toAttorney Docket No. ENX-0159.WO width (e.g., 353), disposed along a face-parallel axis. Entry from a constraint-facing direction (e.g., 707a-707b) may provide faster access to the cell assembly’s center, than entry from a direction orthogonal to 703 (e.g., facing the wide surface of the electrodes).

[0140] Example 750 shows battery cell 752 rolled upon itself about an axis normal to the page (e.g., jelly roll configuration). Battery cell 752 is disposed in housing 751 . During a charge and discharge cycle, the battery expands and contracts. Expansion generates force in the direction perpendicular to the roll axis and toward the battery edges (e.g., along arrows 753). One or more constraints may be added to control the expansion. The contraction and expansion may produce internal pressure. Heat may accumulate in stack interior 754. The heat may be released from the battery along arrows 753. The stacked cell layout shown in example 700 may provide improved thermal conductivity compared to the rolled configuration of example 750. The stacked cell layout shown in example 700 may provide improved diffusion for the entering materials compared to the rolled configuration of example 750. The stacked cell layout shown in example 700 may provide improved diffusion for the entering materials compared to the rolled configuration of example 750.

[0141] In some embodiments, the battery is a rechargeable battery. The battery may undergo cycles of charge and discharge, with one cycle including one change and one discharge operation. The capacity of the battery to store and / or release electrical charge may diminish over the number of cycles it undergoes, e.g, at least in part due to various chemical reactions occurring in the battery during cycling. The reactions may comprise depletion of essential components such as essential chemical(s) for the function of the battery, e.g., depletion of the charge carriers. At least one essential component may be depleted during the first electrolytic cycle of the battery - during buffering, the essential component(s) may comprise starting material for passivation layer of the active material, e.g., SEI layer on an anode active material.

[0142] In some embodiments, the energy manipulation device (e.g., battery) contains critical component(s) required for operation of the cell. The component may comprise a chemical. The critical components may initially be in optimized relative amounts in the battery. Some of the component(s) may enhance some performance attribute(s) while diminishing other attribute(s), e.g., making other attributes worse. A goal for cell performance could be to use an optimized amount of (e.g., critical) components to maximize the benefits while minimizing the drawbacks for best performance of the cell and / or device such as battery. Such optimization may differ in the buffering stage to the optimization in the performance stage - including at least two charging cycles.

[0143] For example, during charging of a cell, charge carriers move from the cathode to the anode. When charge carriers (e.g., lithium cations) come into contact with a starting material (e.g., FEC) they undergo a reduction reaction and form a stable solid electrolyte interphase (SEI) layer on the anode’s surface. The SEI layer (e.g., significantly) improves the cyclingAttorney Docket No. ENX-0159.WO stability of the batteries such as by preventing electrolyte decomposition, e.g., on the anode surface. Although formation of the SEI layer is requested for the stability of the battery, some of the starting materials (e.g., FEC) and the charge carriers become irreversibly bound, and thus removed from the cyclic operation of the battery, e.g., the rechargeable battery. Problems can arise due to the expanding and contracting of the electrode active material such as of the anode. In an example, the SEI layer is formed during charging, when the anode is expanded to a first size. As the battery discharges, the anode contracts to a second smaller size. In some examples, the SEI layer is not sufficiently elastic and as the anode contracts, the SEI layer cracks and / or breaks, thus exposing portions of the anode active material. Such problem may be exacerbated in batteries with electrodes comprising materials (e.g., Si, SiOx, Si-C, etc.) that have large volume differences between their charged and discharged states. The silicon content in the electrode may be at least about 20%, 40%, 50%, 80%, 90%, 95%, 97%, 98%, or 99% wt / wt. The silicon content in the electrode may be between any of the aforementioned percentages, e.g., from about 20% to about 99%, or from about 80% to about 99% wt / wt. In the next charging cycle, the SEI layer may become mended (e.g., clogged) to fix the cracks in the SEI layer caused in the previous cycle. Mending the SEI layer may require additional starting material amount (e.g., FEC), e.g., and charge carriers. In such scenario, the cycle of charging and discharging the battery may result in continual consumption of the starting materials, e.g., and of charge carriers. Buffering may be used to replenish the consumed charge carriers in such case. However, there are currently inadequate solutions to replenish the starting materials required, e.g., the FEC. When the FEC concentration decreases in the electrolyte (e.g., to allow for more cycles of mending the SEI layer), the higher FEC concentration may decrease the efficiency of the battery and / or cause safety concerns for the battery. Higher concentration of FEC may result in generating gas, e.g., the higher the temperature experienced by the battery. Concentrations of FEC above 40% could form solids that decrease the efficiency of the battery. Higher concentration of FEC may increase the impedance of the battery and / or increase the viscosity of the electrolyte. Increasing the viscosity of the electrolyte can reduce the travel rate of the charge carriers in the battery. The gas generated may comprise hydrogen (H2), carbon dioxide (CO2), carbon monoxide (CO), methane (CH4), short aliphatic (e.g., CxH2x+2 such as ethane), or any combination thereof. The active FEC concentration can be most about 0.5%, 1 %, 5%, 10%, 15%, or 30% v / v. The active FEC concentration can be between any of the aforementioned percentage values, e.g., from about 1% to about 20%, from about 0.25% to about 30%, from about 0.25% to about 5%, from about 5% to about 15%, or from about 15% to about 30%. In an example, the cell has at most about 15% active FEC available in the electrolyte mixture.

[0144] The passivation layer may result from an electrochemical reduction of electrolyte component(s) (e.g., FEC) at the electrode interface. The passivation layer may allow chargeAttorney Docket No. ENX-0159.WO carriers (Li+) transport through the passivation layer while hindering (e.g., blocking) electron flow, e.g., to hinder (e.g., prevent) decomposition of other electrolyte components. The passivation layer may stabilize the active material (e.g., of the anode) at least in part by hindering (e.g., impeding or substantially preventing) direct contact between the electrons and the other electrolyte components, thus reducing degradation of the electrolyte and improving cycle life. The passivation layer may comprise inorganic salts, e.g., LiF, IJ2CO3, organic compounds (e.g., lithium alkyl carbonates, Fluoroethylene Carbonate (FEC) and vinylene carbonate (VC) polymerization products). Generation of the passivation layer may consume the charge carriers, e.g., irreversibly. Lithium may be converted into Lithium carbonate and lithium fluoride in the reduction reaction to form the passivation layer, which reaction may be irreversible.

[0145] In some embodiments, charge carriers (e.g., Li ions) reside in a cathode when the battery is in a discharged state, and reside in the anode when the battery is in a charged state. For example, when a battery charges, charge carriers (e.g., carrier ions) migrate into one or more electrode active materials. As the charge carriers traverse (e.g., move) in and out of the active material of the electrodes, the active material undergoes a volume change. The movement in an out of the active material may be referred to as ingress and egress of the charge carriers relative to the active material. The amount of expansion may differ depending on the active materials used for the electrode. For example, a graphite electrode may expand by about 6% to 10% when the graphite electrode is charged. In another example, a silicon electrode may expand up to 300% when the silicon electrode is charged. In another example, a silicon oxide electrode may expand up to 210% when the silicon oxide electrode is charged. In another example, an electrode comprising silicon may expand up to about 20%, 50%, 75%, 100%, 200%, 300%, or 350% when the silicon electrode is charged, the percentage being volume per volume. In some embodiments, graphite electrodes require less starting material (e.g., fluoroethylene carbonate (FEC)) than silicon electrodes because the graphite electrodes expand less. The silicon anode material may have a capacity of at least about 1800 milliampere-hours per centimeter cubed (mAh / CC), 2000mAh / CC, or 2500mAh / CC. The graphite anode material may have a capacity of at most about 800 mAh / CC, 830mAh / CC, or 850mAh / CC.

[0146] In some embodiments, an energy manipulation device such as a battery, comprises a plurality of cells. Each of the cells comprises an anode separated by a gap from a cathode. The gap may comprise a separator. The cell may comprise one or more electrolyte types. Each of the electrodes (e.g., anode and cathode) comprises a current collector, e.g., a strip, a foil, or a film, of conductive material on which the active electrode material is disposed of. The conductive material may comprise an elemental metal, a metal alloy, or an allotrope of elemental carbon. In an example, the elemental metal comprises aluminum or copper. In anAttorney Docket No. ENX-0159.WO example, the metal alloy may comprise stainless steel. In an example, the allotrope of elemental carbon may comprise carbon nanotubes, or carbon fibers. The tubular structures (e.g., nanotubes) may comprise nestled tubes, e.g., at least about 2, 3, 4, or more nestled tubes. The carbon fibers may be weaved, randomly dispersed, or any combination thereof. The strip of conductive material may or may not comprise a composite material. At least two cells in the energy manipulation device (e.g., battery) may be stacked in a direction (e.g., substantially) normal to their face having the largest surface area. The electrode has an electrode face having the largest surface area, and the counter-electrode has a counterelectrode face having the largest surface area. In some embodiments, there is a difference in a volume of the cell between a state of charge and a state of discharge of an electrode of the cell. The volume of the cell may repeatedly and / or reversibly alter between the state of charge and the state of discharge repeatedly. The reversible discharge may not be completely reversible, e.g., there may be an attrition in the properties of one or more components of the cell during a cycle of charge / discharge. The repeated cycling between the state of charge / discharge may comprise at least about 200 cycles, 500 cycles, 800 cycles, 900 cycles, 1000 cycles, 1200 cycles, or 1500 cycles. In some embodiments, there is a difference in a volume of the cell between a state of charge and a state of discharge of an electrode of the cell. The change in volume may comprise a change in at most about 20%, 25%, 50%, 100%, 200%, 300%, or 400% of an initial volume of the cell. The change in volume may comprise a change in at least about 10%, 25%, 50%, 100%, 200%, or 300% of an initial volume of the cell. The change in volume may comprise a change in any of the aforementioned values, e.g., from about 10% to about 400%, from about 100% to about 400%, or from about 20% to about 200%. The charge carriers may interact with the active material (e.g., comprising silicon) such as in an intercalation and / or alloying process (e.g., Li-Si alloying). The Li-Si alloying may form alloys comprising Lii5Si4or l_i22Si5. The lithium alloying of silicon may allow silicon to store at least 5*, 10*, or 15* more lithium as compared to graphite, with the operation “*” designating the mathematical operation of “times.”

[0147] In an example, a passivation layer is formed during operation of the device (e.g., during buffering) that consumes charge carriers and soluble passivating material in the cell. Portions of the passivation layer may be (e.g., additionally) formed during regular operation of the device, e.g., during charging and discharging cycles.

[0148] In some embodiments, electrons are formed in an operation of the cell, which electrons can further react with cell component(s). As the charge carriers move in the battery (e.g., in the cell), electrons are also moving. The electrons may travel from the current collector to the active material coupled with the current collector. When the active material contacts the current collector, such movement of electrons may be direct. When the active material does not contact the current collector, the movement may be indirect. The indirect movement may be throughAttorney Docket No. ENX-0159.WO another active material (e.g., particle), through a conductor, or through a semiconductor. In an example, an allotrope of elemental carbon facilitates the movement of electrons from the current collector to the active material and / or from an active material mass of an electrode to another active material mass of the electrode. The allotrope of elemental carbon may comprise carbon nanotube, carbon fiber, any plurality of types thereof, or any combination thereof. The electrons may react with one or more chemicals in the device such as in the cell, e.g., some of which reactions may be detrimental to the battery’s chemistry such that they diminish (e.g., harm) the device’s requested performance. For example, the electrons may destabilize metal oxides during the charge / discharge cycles, e.g., due to slippage of transition metal layers, phase transitions and / or electrochemical strain. Mitigation (e.g., reduction) of the reactivity of the electrons in the battery cell may include causing confinement of the electrons to retard (e.g., reduce, deter and / or substantially prevent) reaction of the electrons with the material(s) in the device, e.g., during the prescribe operation conditions of the battery and / or during the prescribed lifetime of the device such as battery. Generation of a passivation layer that helps confine the electrons in the active material mass and / or impede their reaction with components of the device (e.g., of the cell) external to the passivation layer, may mitigate the harmful reactivity of the electrons.

[0149] In some embodiments, the energy manipulation device has prescribed conditions and / or a prescribed lifetime. Operation of the device (e.g., battery) may be during its prescribed lifetime, during its prescribed use, and / or according to jurisdictional standards relating to the device related standards. The prescribed lifetime may depend at least in part on the number of charge and discharge cycles, e.g., as disclosed herein. The number of cycles may be to full charge before the capacity of the device (e.g., battery) drops below 80%. The prescribed lifetime may be of at most about 3 years, 5 years, 6 years, 7 years, or 10 years, e.g., from the date of its manufacture. The device may have a shelf life of at least about 6 months, 12months, 15months, or 24 months. The standards may include, MIL-STD-810G (516.6), UL (e.g., UL1642 and / or UL 2054), SAE (e.g., SAE J2380), GB (e.g., GB31241 and / or GB31242), MSDS, UL (UL1642 and / or UL2054), CE, CB, UN (e.g., UN38.3 and / or UN38.4), RoHS, REACH, IEC (e.g., IEC 60068-2-6, IEC 60068-2, and / or IEC62133), DOT, IATA, GB, CTIA, PSE, SICIT, IEEE (e.g., IEEE 1726), CCC certification , CN (e.g., CNS15265), BSMI, or any combination thereof. The prescribed operating conditions comprise temperatures between a lower temperature (e.g., -20°C) and a higher temperature (e.g., 80°C). The higher temperature may be of at most about 60°C, 70°C, 80°C, 85°C, or 90°C. The higher temperature may be of at least about 40°C, 50°C, 55°C, 60°C, 70°C, or 80°C. The lower temperature may be of at most about -10°C, -20°C, -30°C, -40°C, or -50°C. The lower temperature may be of at least about -20°C, -10°C, or 0°C. The temperature may be between any of the aforementioned values, e.g., from about 60°C to about -20°C, or from about 90°C to about -40°C. The deviceAttorney Docket No. ENX-0159.WO may retain at least about 70%, 80%, or 85% of its capacity the lower temperature as compared to its capacity at ambient temperatures, e.g., at room temperature such as 20°C or 25°C.

[0150] In some embodiments, the energy manipulation device is rechargeable. The device may be configured to allow fast charging (e.g., allowing the cell(s) to fully charge in five minutes). The device may have a C-rate of at least about 0.2C, 0.5C, 1 C, 2C, 3C, 5C, 7C, 10C, 12C, or 15C, 30C, or 40C. The C-rate may be charging the device to 80% capacity, or to 90% capacity. The device may have a C-rate of any value between any of the aforementioned values, e.g., from about 0.2C to about 40C, from about 02C to about 5C, from about 3C to about 30C, from about 10C to about 40C or from about 2C to about 7C. The device may be charged to at most about 30sec, 3 min. 6min. 10min, 12min, 15 min, 30min, the charging being to 80% or to 90% capacity. The device may allow to choose the mode of discharge and / or of charge. The discharge and / or of charge, may be in a continuous mode, in a pulsed mode, or in a combination of a continuous mode and pulsed mode. In some embodiments, the battery has a N / P ratio greater than one. The N / P ratio may be at least about 1.05, 1.1 , or 1.15. The cell configuration, cell set architecture, and / or chemical makeup (e.g., of the electrode active material(s)), may allow for buffering such as pre-lithiation. The cell, cell set, and / or battery disclosed herein, may facilitate maintenance of cyclable charge carriers (e.g, lithium) in the anode, e.g., also at beginning of charge (BOC). The cell, cell set, and / or battery disclosed herein may provide for better conductivity and / or for lower overpotential in anode deposited material (e.g., cake comprising the active material). The cell, cell set, and / or battery disclosed herein may provide for reduced (a) cycling window and / or (b) damage due at least in part to expansion and contraction during the charge and discharged states of the cell. The cell, cell set, and / or battery disclosed herein may provide for high voltage at BOC, e.g., without buffering, e.g., without pre-loading of the charge carrier into the active material of the electrode such as in a pre-lithiation process. The nominal voltage of the device may be at least about 3.6 Volts (V), 3.7V, 3.8V. The working voltage of the device may be at least about 3V, 3.7V, 3.8V, 4.0V, 4.2V, 4.35V, 4.5V, 4.75V, 4.9V, or 5.0V. The working voltage of the device may be between any of the aforementioned values, e.g., from about 3V to about 5V, from about 3V to about 4V, or from about 4V to about 5V. The weight of the device may be at most about 1 gram(gr), 1.5gr, 1.8gr, 2gr, 3.5gr, 6gr, 46gr, 47gr, 50gr, 69gr, 70gr, 71 gr, or 100gr. The weight of the device may be at any value between any of the aforementioned values, e.g., from about 1.8gr to about 100 gr. The volumetric energy density of the device may be at least about 500 Watt hour per liter (Wh / liter), 600Wh / liter, 800Wh / liter, 805 Wh / liter, 820 Wh / liter, 900 Wh / liter, 1300 Wh / liter, or 1500 Wh / liter. The gravimetric density of the device may be of any value between any of the aforementioned values, e.g., from about 500 Wh / liter to about 1500 Wh / liter. The gravimetric energy density of the device may be at least about 150 Watt hours per kilogram (Wh / kg), 200 Wh / kg, 250 Wh / kg, 300 Wh / kg, 320 Wh / kg, 350 Wh / kg, 395 Wh / kg,Attorney Docket No. ENX-0159.WO400 Wh / kg, 500Wh / kg, 1000 Wh / kg, 2000 Wh / kg or 3000 Wh / kg. The gravimetric density of the device may be of any value between any of the aforementioned values, e.g., from about 150 Wh / kg to about 3000 Wh / kg, from about 200 Wh / kg to about 400 Wh / kg, or from about 400 to about 3000 Wh / kg. The energy density (e.g., whether volumetric or gravimetric) may be measured at about 50%, 40%, 30% or 20% state of charge. The electrical charge capacity of the cell may be of at least about 200 milliampere hours (mAmph), 240 mAmph, 280 mAmph, 600 mAmph, 900 mAmph, 1 Amper hour (Amph), 5Amph, 7Amph, 7.35 Amph, 10 Amph, 30 Amph, 50 Amph, or 70 Amph. The electrical charge capacity of the cell may be between any of the aforementioned values, e.g., from about 200 mAmph to about 800 mAmph, from about 200 mAmph to about 1 Amph, from about 1 Amph to about 30 Amph, from about 1 Amph to about 10 Amph, or from about 30 Amph to about 80 Amph.

[0151] In some embodiments, the anode comprising silicon is thinner than an anode comprising graphite, e.g., has a smaller height - Fig. 2, 205. The anode height may be at most about 30%, 35%, 40%, 50%, 65%, 75%, or 80%, height (i.e. , thickness) of a graphite anode for a for a given loading of anode active material. The anode height may be at least about 10%, 20%, 30%, 35%, 40%, 50%, 65%, or 70%, height (i.e., thickness) of a graphite anode for a for a given loading of anode active material. As compared to a graphite anode for a for a given loading of anode active material, the anode height may be between any of the aforementioned percentages, e.g., from about 10%, to about 70%, or from about 30% to about 70%. In an example, the height difference in graphite anode vs. silicon anode when discharged is 35%. In an example, the height difference in graphite anode vs. silicon anode is anode is 65% of the size of the graphite anode for a given loading, when each of the anodes is fully formed. A thinner anode may allow for better current distribution through the electrode and / or lower likelihood of charge carrier plating (e.g., reduction to its elemental state) such as lithium plating.

[0152] In some embodiments, the cell is pre-loaded with charge carriers, e.g., to form an initial passivation layer. During the initial charge process (e.g., buffering such as pre-lithiation), certain starting materials (e.g., FEC) are consumed to contribute to the formation of a passivation layer, e.g., an SEI layer. The passivation layer may be the result of the electrons and / or charge carriers reacting with the electrolyte in a reduction reaction. In some embodiments, the electrolyte(s) is / are chosen such that the reduction reaction results in the passivation layer having certain properties. For example, the passivation layer may comprise a solid or semisolid (e.g., gel). The passivation layer may be porous, e.g., to allow the charge carriers to migrate into and out of the electrode active material, e.g., silicon and / or graphite. The passivation layer may allow charge carriers (e.g., Li+) to pass through it while hindering (e.g., blocking) electron flow, to reduce (e.g., prevent) decomposition of electrolyte(s). The passivation layer may stabilize the active material, e.g., at least in part by hindering (e.g., preventing) direct contact of the electrode active material with any active components (e.g., ofAttorney Docket No. ENX-0159.WO the electrolyte mixture), such that degradation of critical cell component(s) is reduced and / or the cycle life of the battery (e.g., the cell) is improved, in comparison to a situation in which no passivation layer is formed. The passivation layer may comprise a (e.g., inorganic) salt, an organic compound, a polymer, a resin, a composite, any plurality thereof, or any combination thereof. The salt may be the salt of the charge carrier. The organic compound may be made from a carbonate precursor. The organic compounds may comprise, or may be made of a precursor comprising, lithium alkyl carbonates, fluoroethylene carbonate (FEC), vinylene carbonate (VC), polymerization products thereof, any plurality of types thereof, or any combination thereof. In some embodiments, the passivation layer comprises a different chemical form of the charge carriers such as lithium. The passivation layer may (e.g., readily) form (e.g., deposit) on one or more surfaces of the active material of the cell, e.g., of the electrode and / or of the counter-electrode. The passivation layer may be a decomposition product comprising the charge carriers and / or electrolyte mixture components. Although formation of the passivation layer may be requested for the stability of the battery and / or cell thereof, some of the starting materials (e.g., FEC) and / or the electrons, may be irreversibly bound to the passivation layer, and thus are removed from regular operation of the cell, e.g., during its charge and discharge cycles.

[0153] In some embodiments, the cell comprises an electrolyte mixture. The electrolyte mixture may comprise salt, solvent, additive, any plurality of types thereof, or any combination thereof. The electrolyte mixture may be non-aqueous. The electrolyte mixture may comprise an organic mixture. The electrolyte may comprise polar molecule. The electrolyte may be sufficiently polar to dissolve the charge carriers such that they are readily available to participate in the charge and / or discharge cycles. The electrolyte may be such that side reaction with any other device components are minimized, e.g., during the prescribed lifetime of the device and / or in the prescribed use conditions of the device. The salt may comprise a halogen salt, a borate salt, an imide salt, a sulfonyl salt, any derivatives thereof, or any combination thereof. In the case of Lithium charge carrier, the salt may comprise Lithium hexafluorophosphate (LiPFe), Lithium tetrafluoro borate (LiBF ), Lithium bis(fluorosulfonyl)imide (LiFSI), any derivatives thereof, or any combination thereof. The solvent may comprise a carbonate, a propionate, an ethyl acetate, any derivatives thereof, or any combination thereof. The solvent may compromise Ethylene carbonate (EC), Propylene carbonate (PC), Ethyl methyl carbonate (EMC), Diethyl carbonate (DEC), Propyl Propionate (PP), Ethyl Propionate (EP), Difluoro ethyl acetate (DFEA), or Methyl (2,2,2-trifluoroethyl) carbonate (FEMC), any derivatives thereof, or any combination thereof. The additive may comprise a carbonate, a nitrile (e.g., mono, bi, and / or thri- nitrile), a cyanide, an ethoxy, an ethylene, a sultone, any derivatives thereof, or any combination thereof. The additive may comprise fluoroethylene carbonate (FEC), Vinylene carbonate (VC), Vinyl ethylene carbonateAttorney Docket No. ENX-0159.WO(VEC), Succinonitrile (SN), adiponitrile (AN), 1 ,3,6-hexanetricarbonitrile (HTCN), 1 ,2-Bis(2- cyanoethoxy) ethane (DENE), propane sultone (PS), 1 ,3-propene sultone (PRS), any derivatives thereof, or any combination thereof.

[0154] In some embodiments, the active material comprises a passivation layer. The passivation layer may range in thickness of at least about 30 nanometers (nm), 50 nm, 100 nm, 150 nm or 200 nm. The passivation layer may range in thickness of at most about 50 nm, 100 nm, 150 nm, 200 nm, or 250 nm. The passivation layer may range in thickness between any of the aforementioned values, e.g., from about 50 nanometers (nm) to about 150 nm, or from about 30 nm to about 250 nm. The passivation layer may be configured to allow charge carriers to pass through, and hinder (e.g., prevent) electrons in passing through.

[0155] In some embodiments, the passivation layer comprises an SEI layer. The SEI layer may comprise the charge carrier such as lithium, e.g., in the form of salt(s) such as lithium fluoride (LiF) and / or Li2CO3. In some embodiments, the SEI layer comprises inorganic salts, and / or organic compounds. The organic compounds may comprise lithium alkyl carbonates, fluoroethylene carbonate (FEC), vinylene carbonate (VC), polymerization products thereof, a plurality of types thereof, or any combination thereof. In some embodiments, the SEI layer comprises lithium. The SEI layer may (e.g., readily) form (e.g., deposit) on one or more surfaces of the electrode active material. The SEI layer may be a decomposition product comprising lithium (or other carrier ions) and / or electrolyte mixture components. Although formation of the SEI layer is requested for the stability of the battery, some of the starting materials of the passivation layer (e.g., FEC) and / or the electrons, may be irreversibly bound to the SEI, and thus are removed from the regular operation of the cell, e.g., during its charge and discharge cycles.

[0156] In some embodiments, a passivation layer is formed, the passivation layer contacting an external surface of the active material, e.g., cathode and / or anode active material. The concentration of the starting material in the electrolyte (e.g., FEC) in the electrolyte may be between about 15% to about 30% volume of active FEC per volume of electrolyte. The concentration of the starting material may be at most about 0.25%, 0.5%, 1 %, 5%, 10%, 15%, or 30% volume of starting material per volume of electrolyte. For example, the concentration of starting material may be at most about 15% volume of starting material per volume of electrolyte. The concentration of starting material may be of any percentage value between any of the aforementioned percentage values, e.g., from about 0.25% to about 30%, from about 0.25% to about 5%, or from about 5% to about 15%, volume of starting material per volume of electrolyte.

[0157] In some embodiments, the cell comprises an anode separated by a gap from an anode. The cell may comprise a separator disposed in the gap. The cells may be elongated, e.g., may assume a shape of an elongated box. The face of the cell opposing the largest surface areaAttorney Docket No. ENX-0159.WO face of the electrode (e.g., anode or cathode) may have an aspect ratio of at least about 10:1 , 15:1 , 20:1 , 35:1 , or 50:1 , the aspect ratio being a length (e.g., Fig. 6, 631) of the face to a height (e.g., Fig. 6, 632) of that face. The cell may have an aspect ratio of at least about 5:1 , 8: 1 , 10:1 , 15:1 , 25:1 20:1 , 35:1 , or 50:1 , the aspect ratio being a height (e.g., Fig. 6, 632) of the cell to a width.

[0158] In some embodiments, the architecture of the device comprising the stacked electrodes described herein (e.g., Figs. 3, 5 and 6) allow for better (e.g., faster and / or homogenous) distribution of starting materials (e.g., FEC) into the cell, as compared to other cell arrangements. The other cell arrangements may include a folded (e.g., jelly roll) cell configuration, or cell having a smaller aspect ratio, e.g., and having vertically stacked electrodes. In an example, when the electrodes have a large aspect ratio - are elongated, (e.g., and are stacked such along a horizontal axis such as in Fig. 3, 350), starting materials introduced at the long edges of the electrodes (e.g., top and / or bottom of the device), may quickly reach the middle of the electrode height (e.g., 351), e.g., since the distance to the interior of the cell structure is shorter, e.g., relative to a situation in which the starting material(s) is / are introduced (A) at the side edges of an elongated cylinder (e.g., 300), or (B) at edges of electrodes having a smaller aspect ratio (e.g., and that are stacked along a vertical axis Fig. 3, 330).

[0159] The prescribed use of the device (e.g., battery) comprises during charge-discharge cycling, during transportation, during storage, during maintenance, during upgrade, or any combination thereof. The prescribed use of the cell assembly comprises during formation of the cell assembly, during buffering of the cell assembly, during the prescribed use of the device comprising the cell assembly (e.g., the battery), or any combination thereof. The normal operation conditions of the device may be such that the device (e.g., minimally) abides by jurisdictional standards, and / or industry standards.

[0160] In some embodiments, the energy manipulation device comprises a battery enclosure, e.g., housing. The enclosure may comprise a pouch e.g., may be a pouch. The battery enclosure may comprise a first enclosure portion and a second enclosure portion. The first enclosure portion may be coupled with the second enclosure portion. The coupling of each of the enclosure portion may form a sealed enclosure such as a sealed pouch. The enclosure may be configured to house the cell assembly. The cell assembly may comprise one or more unit cells such as stacked unit cells. A unit cell can comprise a cathode, an anode, and a separator. The cell assembly may comprise electrode tabs, e.g., the electrode tabs being a cathode tab and an anode tab. The electrode tabs may partially extend from the seal of the enclosure. The cell assembly may comprise grommets, e.g., to provide a seal for the electrode tabs. The grommets may partially extend from the pouch. The battery enclosure (e.g., pouch) may provide protection against physical damage for the enclosed cell assembly, e.g., duringAttorney Docket No. ENX-0159.WO transport of the device. The enclosure may provide a sealed environment to seal gas, liquid, and / or solid (e.g., pulverous) material therein. The enclosure may provide isolation from environmental factors, e.g., during the life of the battery. The environmental factors may comprise one or more reactive species such as disclosed herein. The enclosure may provide structural integrity of the cell assembly, e.g., during operation of the device such as the prescribed operation of the device disclosed herein. The battery enclosure may support the durability of the battery, e.g., over the device lifespan such as its prescribed lifetime as disclosed herein.

[0161] In some embodiments, the first enclosure portion is configured to couple with the second enclosure portion to form the enclosure. The first enclosure portion and second enclosure portion may be coupled by an adhesive, mechanical means, temperature application, pressure application, or any combination thereof. The enclosure (e.g., and any portion thereof) may comprise one or more layers. The layering techniques may comprise deposition, lamination, binding, pressing, heating, any plurality of types thereof, or any combination thereof. The enclosure portions may be sealed together. The enclosure may comprise a central body and an extension at the perimeter of the central body. An internal space (e.g., volume) of the central body may comprise the cell assembly, any constraint system, the electrolyte, any charge carriers, or any combination thereof. Sealing of the enclosure may take place at the perimeter of each of the enclosure portions, e.g., around the central body portion of the enclosure and at the extension portion of the enclosure. The enclosure portions may (e.g., substantially) seal the cell assembly therewithin. The enclosure portions seal the enclosure at least in part by binding the first portion with the second portion, with sections of the terminal tabs (and their surrounding grommets) propagating from the interior of the central body, through the seal, to the exterior environment (e.g., ambient environment) of the enclosure. The enclosure layers may be completely sealed including the tabs. Sealed may comprise hermetic seal such as fluid tight seal. The hermetic seal may seal in the enclosure solids (e.g., powder), liquid (e.g., electrolytes), gas (e.g., generated gas such as carbon dioxide, methane, and / or hydrogen), any plurality of types thereof, or any combination thereof. The fluid tight seal may comprise gas tight seal, liquid tight seal, or any combination thereof. The sealed enclosure may hinder (e.g., substantially and / or measurably prevent) ingress of reactive species from the ambient environment into the enclosure, e.g., during the prescribed lifetime of the device such as disclosed herein. The enclosure seal may be different around the terminal tabs (e.g., around their respective grommets), e.g., to account for geometry of the tabs. The enclosure portions may be sealed overthe grommets, which can act as an additional, or a dedicated, seal for the terminal tabs.

[0162] In some embodiments, the first enclosure portion is configured to house the cell assembly. The first enclosure portion may comprise a structure having a receiving volume,Attorney Docket No. ENX-0159.WO e.g., a depression forming a bowl, or a cup. The receiving volume may be configured to include all device components destined to be protected from the external environment or components that cannot be separated from the components that require protection from the external environment, e.g., the active material, current collectors, its associated interconnect components (e.g., any busbars, busbar extensions), electrolyte, charge carriers, any charge carrier precursor, insulating material (e.g., porous layer), separators, any constraint system, any protection layer for the constraint system (e.g., PPL), or any combination thereof. The receiving volume may be configured to accommodate the volume of the electrode assembly, e.g., along with any busbars, insulating material (e.g., porous material such as alumina and / or boehmite), constraint system, protection layer (e.g., PPL), or any combination thereof. The first enclosure portion may comprise an open top box geometry, a cup-shaped container geometry, a polygonal recess, or any combination thereof, e.g., depending at least in part on the shape of the cell assembly and / or any constraint system thereof. The first enclosure portion may have a depth, e.g., three dimensional (3D) shape having a depth. The depth may be sufficient to house the thickness of the cell assembly while leaving an open face for a second lid portion to be coupled with the first enclosure portion, e.g., in the subsequent sealing operation. The first enclosure portion may provide the structure for the enclosure wall(s). The first enclosure portion may be pre-formed (e.g., deep-drawn), e.g., to define the open top (e.g, box) shape, e.g, before the insertion of the cell assembly. The pre-formation of the first enclosure portion, may be influenced at least in part by the buffering procedure.

[0163] In some embodiments, the second enclosure portion is configured to enclose the housed cell assembly, e.g., within the first enclosure portion. The second enclosure portion may be a lid. The lid may be positioned over the open face of the first enclosure portion, e.g., over the cup portion of the enclosure. The second enclosure portion may be a planar (e.g., flat) sheet. Any portion of the enclosure may comprise a flexible material. The second enclosure portion may be placed over the first enclosure portion containing the cell assembly and any of its associated components that require shielding from the external environment, e.g., as disclosed herein. When sealed (e.g., via heat and / or pressure sealing), the peripheral portions (e.g., extension) of the first and second enclosure portions, may form flaps extending outwardly from the main enclosure, e.g., that directly surrounds the cell assembly. The enclosure portions may be trimmed to a requested dimensions, before, during, and / or after, the sealing operation. The trimming may reduce the overall dimensionality of the coupled enclosure layers, e.g., reduce the lateral dimensionality of the extension.

[0164] In some embodiments, the enclosure may comprise a barrier material that substantially hinders reactive species from the ambient atmosphere from entering into the enclosure interior. The barrier material may comprise metal. The metal may comprise elemental metal, a metal alloy, a plurality of types thereof, or any combination thereof. The enclosure may comprise oneAttorney Docket No. ENX-0159.WO or more layers of metal. The enclosure may be made of metal, e.g., a can. The enclosure may comprise a metallic material and one or more organic layers. The organic layers may be carbon based and / or silicon based. At least one of the organic layers can allow in-situ binding of the first and second enclosure portions using heat pressing such as while the sensitive material are disposed in the enclosure interior, the materials being sensitive to the reactive species present in the ambient environment. At least one of the organic layers can be configured for low temperature adhesion with another (e.g., such) organic layer. The low temperature adhesion organic layer of the first enclosure portion (e.g., cup portion) may be configured to find to the low temperature adhesion organic layer of the second enclosure portion (e.g., lid portion). In other embodiments, the cup portion may be a second portion, and the lid may be the first portion. The low temperature organic layer may be disposed in an interior of the enclosure material, e.g., to allow low temperature sealing of the enclosure portions with one another. The enclosure may comprise a layerwise structure having a first organic layer, a first barrier material layer, and a second organic layer. The first organic layer may be more sturdy, durable, stiff, and / or robust, as compared to the second organic layer. The first organic layer may be configured to better withstand physical impact (e.g., scratching and / or wrinkling), as compared to the second organic layer. The second organic layer may be configured for lower temperature phase change that allows its adhesion. The phase change may comprise glass transition, flowability, liquification, melting, creeping, or any combination thereof. The phase change may be configured to allow two similar layers (e.g., one of the cup and one of the lid) to adhere with each other upon temperature and / or pressure elevation. The temperature may be sufficiently low to prevent thermal runaway in the cell assembly. The sealing of the first and second enclosure portions may be while the cell assembly is disposed in the enclosure, e.g., referred to herein as in situ sealing.

[0165] In some embodiments, the multi-layer material comprises a combination of organic layers and barrier (e.g., metallic) layer(s), configured for use in the enclosure. An organic layer may comprise a polymer, a resin, a plurality of types thereof, copolymers thereof, a mixture thereof, or any other combination thereof. The organic layers may comprise a first and second organic layer, e.g., first and second layers of the layerwise material. At least one organic layer of the layerwise structure may comprise polyamide (e.g., nylon), polypropylene, polyphthalamide, polyethylene, polyethylene terephthalate, polybutylene terephthalate, polyvinylidene fluoride, polyimide, polyester, polycarbonate, polyvinylidene chloride, any plurality of types thereof, or any combination thereof. The organic layers may facilitate mechanical robustness, puncture resistance, scuff resistance, heat-sealability, or any combination thereof, e.g., of the enclosure. The organic layers may comprise primers, tie layers, adhesives, lacquer layers, heat-seal coatings, polyurethane-based adhesives, epoxybased adhesives, acrylic-based adhesives, any plurality of types thereof, or any combinationAttorney Docket No. ENX-0159.WO thereof. The heat-seal coatings may comprise polyolefin-based adhesives such as maleic- anhydride-grafted polyolefins. The organic layers may be configured to promote adhesion between similar materials and / or dissimilar materials. The organic layers may tune the seal strength and / or sealing initiation temperature. The barrier layer may comprise a metal, high- barrier organic, or any combination thereof. At least one of the barrier layer may comprise a composite material, or a non-composite material. The barrier material may comprise an elemental metal, a metal alloy, any plurality of types thereof, or any combination thereof. The barrier material may comprise aluminum, an aluminum alloy, steel, a steel alloy, nickel, copper, ethylene-vinyl alcohol (EVOH), polyvinylidene chloride (PVDC), or any combination thereof. The barrier layer may be configured to provide a moisture barrier, oxygen barrier, light barrier functionality, or any combination thereof. The multi-layer material may comprise functional layers configured to interface with other components disclosed herein, e.g., with (i) resin and / or polymer layers, (ii) external rigid enclosures (e.g., constraint), (iii) (e.g., neat) bonding agent(s), (iv) tape(s), or (v) any combination thereof. The bonding agents may comprise hot-melts, polyurethane glues, epoxy glues, cyanoacrylate glues, any plurality thereof, or any combination thereof, such as disclosed herein. The neat bonding agent may be in the form of a fluid, creeping agent, or otherwise flowable. The tape may be a double sided tape. The adhesive (e.g., neat or disposed in a form of a tape matrix) may be used to secure the enclosure portions, fuse structures, protective layers, or any combination thereof. The adhesive used for the fuse structure and / or interconnect component may differ from the adhesive used for the enclosure. The adhesive used for the fuse structure and / or interconnect component may be electrically conductive. The adhesive used for the enclosure may be electrically insulating.

[0166] In some embodiments, the layer(s) comprise at least one layer of organic material and at least one layer of a barrier (e.g., metallic) layer. A layer of the barrier material may have a thickness of at least about 10 micrometers (pm), 20 pm, 30 pm, 35 pm, 50 pm, or 100 pm. The layer of the barrier material may have a thickness of at most about 30 pm, 35 pm, 40 pm, 50 pm, 70 pm, 100 pm, 120 pm, 160, or 180 pm. The layer of the barrier material may have a thickness between any of the aforementioned values, e.g., from about 10 pm to about 180 pm, or from about 10 pm to about 50 pm. Each of the layer(s) (e.g., organic layers) may have a thickness of at least about 10 micrometers (pm), 20 pm, 30 pm, 35 pm, 50 pm, or 100 pm. Each of the layer(s) may have a thickness of at most about 30 pm, 35 pm, 40 pm, 50 pm, 70 pm, 100 pm, 120 pm, 160, or 180 pm. Each of the layer(s) may have a thickness between any of the aforementioned values, e.g., from about 10 pm to about 180 pm, or from about 10 pm to about 50 pm. The layers of the layerwise structure may collectively have a thickness of at least about 70 pm, 80 pm, 85 pm, 90 pm, 100 pm, 120 pm, 160 pm, or 180 pm. The layers of the layerwise structure may collectively have a thickness of at most about 90 pm, 105 pm, 1 10 pm, 120 pm, 150 pm, 200 pm, or 250 pm. The layers of the layerwise structure may collectivelyAttorney Docket No. ENX-0159.WO have a thickness between any of the aforementioned values, e.g., from about 10 m to about 180 pm, or from about 10 pm to about 50 pm. The layerwise structure may have a layer having a thickness (e.g., substantially) the same as the thickness of at least one other layer of the layerwise structure, e.g., the metallic layer can have a thickness as an organic layer. The layerwise structure may have a layer having a thickness smaller than (e.g., a fraction of) the thickness of at least one other layer of the layerwise structure. In an example, the barrier (e.g., metallic) layer has a thickness greater than that an organic layer of the layerwise structure, such as greater by at least about 1.5 times. In an example, one organic layer has a thickness greaterthan that of another organic layer of the layerwise structure, such as greater by at least about 1.5 times. The fraction can be at most about 0.75, 0.5, 0.25, or 0.1. The fraction value can be between any of the aforementioned fractions, e.g., from about 0.75 to about 0.1.

[0167] In some embodiments, each of the first and second enclosure portions, comprises a multi-layer material. The multi-layer material may comprise a plurality of layers to form a layerwise structure such as disclosed herein. The multi-layer material may comprise three or more layers. The multi-layer material may comprise a first layer. The first layer may face away from the cell assembly and towards an ambient environment. The first layer may contact the ambient environment. The first layer may comprise an organic material such as disclosed herein. In an example, the first layer comprises nylon. The multi-layer material may comprise a second layer. The second layer may be positioned adjacent to the first layer. The second layer may face and / or contact the cell assembly, e.g., by contacting the constraint system in which the cell assembly is disposed. The second layer may comprise an organic material such as disclosed herein. In an example, the second layer comprises a mixture of polyphthalmide and polypropylene. The multi-layer material may comprise a barrier layer. The barrier layer may be positioned between the first and second layer, e.g., and coupled with the first and second layer to form the layerwise structure. The barrier layer may be devoid of direct contact with the cell assembly, with the constraint system enclosing the cell assembly, and / or with an external environment to the enclosure. The multi-layer material may be configured for protecting the cell assembly from external influences, e.g., from ingress of the reactive species present in the ambient environment. The multi-layer material may be configured for protecting the external environment from harmful materials associated with the cell assembly, e.g., from egress of the harmful material to the ambient environment. The harmful material may compromise active anode material, active cathode material, electrolytes, charge carriers, charge carrier precursors, reaction products generated during operation of the device (e.g., prescribed use of the device), or any combination thereof. The sealed enclosure may generate a physical protection barrier between the interior environment of the enclosure and the ambient environment. The sealed enclosure may be configured to maintain such barrier during the prescribed use and / or lifetime of the device, such as disclosed herein.Attorney Docket No. ENX-0159.WO

[0168] In some embodiments, the pouch comprises a plurality of flaps. The flaps may be disposed in an extension of the enclosure from the central body of the enclosure, e.g., as disclosed herein. The trimming may be performed by mechanical cutting. The trimming may comprise die cutting, rotary cutting, reciprocal cutting, laser cutting, fluid jet cutting, or any combination thereof. The trimming may be performed by mechanical cutting, chemical cutting, non-mechanical physical cutting, or any combination thereof. The chemical cutting may comprise corrosion, e.g., using acid. The mechanical cutting may comprise a blade, e.g., of a knife. The non-mechanical physical cutting may comprise a laser, e.g., using spallation, ablation, melting, or any combination thereof. The central body may comprise one or more side walls. The central body may be a cylinder, e.g., comprising one side wall. The central body may be a prism such as a box, e.g., having four side walls. The enclosure may comprise one or more fold lines. The fold line(s) may be disposed at the periphery of the central body where it contacts the extension portion. The extension may comprise the flaps and folds. The folds may be also referred to as “corner protrusions” or “bat ears." A fold may contact two immediately adjacent flaps along the extension, with an immediately adjacent flap being devoid of a flap disposed therebetween. A flap may contact two immediately adjacent folds along the extension, with an immediately adjacent fold being devoid of a fold disposed therebetween. The enclosure may comprise a respective fold line associated with a flap. The flap may fold along its respective fold line, to contact and adhere with the respective wall of the central body towards which it is folded. The fold line may comprise an unperforated line, an uncreased line, or otherwise not delineated line. The fold line may define a location about which the flap is configured to be folded. The flap may immediately contact with central body, without having another portion of the layer(s) of the enclosure material disposed therebetween, e.g., except for an adhesive such as a tape and / or a neat adhesive (e.g., liquid adhesive).

[0169] In some embodiments, all flaps of the extension of the enclosure, are folded such that they have a vectorial component in a direction. The direction may be along a wall of the central body of the enclosure. The cell assembly may comprise a unit cell having an anode stacked about a stacking axis with a cathode. The cell assembly may comprise a plurality of the unit cell - being unit cells - that are stacked along the stacking axis. The vectorial component may be in a direction normal to the stacking axis. The central body may have a face type having the largest surface area. The vectorial component may be normal to the face type having the largest surface area among face types of the central body. The vectorial component may be a portion of the direction, or the entire direction. By folding all the flaps to contact the wall(s) of the central body, the footprint of the device is reduced, increasing its energy density, e.g., as compared to a situation in which at least one of the flaps is not folded.

[0170] In some embodiments, the enclosure comprises folds, e.g., as part of the extension of the enclosure. The folds may be generated as a consequence of folding the flaps that areAttorney Docket No. ENX-0159.WO coupled with the wall(s) of the enclosure. The folds may be remainders of the extension portion that is not immediately coupled with the walls of the central body (e.g., through an adhesive). A flap may have two lateral opposing folds, with each fold disposed at a lateral distal end of the flap, forming a pair of flaps. To reduce the footprint of the device, the folds may be folded along fold lines. The fold lines along which the folds are folded, may be (e.g., substantially) disposed at an angle relative to the fold lines along which the flaps are folded. The fold lines along which the folds are folded, may be (e.g., substantially) perpendicular to the fold lines along which the flaps are folded. The pair of folds may contact and couple with the flap, e.g., such that ends of each of each of the folds face each other. The pair of folds may contact and couple with an immediately adjacent flap. The flaps may form a series of flaps disposed successively along the side(s) of the central body. The side of the central body may constitute the wall of the central body. The flaps may sequentially and interchangeably with a fold and not couple with a fold. The flaps may sequentially and interchangeably with a pair of fold, and not couple with a pair of folds. In an example, the folds are folded such that a first flap is devoid of folds, a second flap has two folds attached to it - the two folds facing each other, a third flap devoid of folds, and a fourth fold having two folds attached to it - the two folds facing each other. By folding all the folds to (indirect) contact the wall(s) of the central body, the footprint of the device is reduced, increasing its energy density, e.g., as compared to a situation in which at least one of the folds is not folded. The folds may be folded such that they directly attach with the central body, or that they attach with central body at least in part by being attached with the flap. The folds may be folded first to directly attach with the central body. The folds may be folded after folding the flaps such that that they attach with central body at least in part by being attached with the flap. A structure in which the flap is immediately in contact with a side (e.g., wall) of the central body, and the fold (or pair of folds) contacts the central body at least in part by contacting the flap, may allow a tighter geometry (and higher density) as compared to another example in which the folds are immediately in contact with a side (e.g., wall) of the central body, and the flap contacts the central body at least in part by contacting the pair of folds. Such structure may entail simpler and more robust folding procedure as compared to the folds being folded first. A structure in which the folds are immediately in contact with a side (e.g., wall) of the central body, and the flap contacts the central body at least in part by contacting the folds, may better secure the folds from being inadvertently dislodged, as compared to another example in which the folds are immediately in contact with a side (e.g., wall) of the central body, and the flap contacts the central body at least in part by contacting the pair of folds. Such structure may entail a more demanding folding procedure, and may be more appropriate for a device having an enclosure that can face such inadvertent dislodging, e.g., when the device is anticipated to be manipulated frequently by a user. The folds may be also referred to as “corner protrusions” or “bat ears.”Attorney Docket No. ENX-0159.WO

[0171] In some embodiments, the central body comprises sides. In some embodiments, the flaps comprise a first side flap. The first side flap may extend from at first side wall of the central body at a first fold line of the enclosure. The flaps may comprise a second side flap. The second side flap may extend from a second side wall of the pouch at a second fold line of the pouch. The second side wall may be positioned opposite the first side wall. The flaps may comprise a third flap, e.g., an end flap. The third flap may extend from a third wall at a third fold line. The third wall may extend laterally from the first side wall to the second side wall, e.g., to couple the first side wall and the second side wall along a circumference of the central body. The third wall may be (e.g., substantially) perpendicular to the first and second side walls. The enclosure may comprise a fourth wall. The fourth wall may be positioned opposite the first end wall. The fourth flap may extend from a tab end wall of the central body at a fourth fold line. The fourth wall may extend from the first side wall to the second side wall, e.g., to connect the first and second side walls. The fourth wall may be (e.g., substantially) perpendicular to the first and second side walls. One or more terminal tabs may extend outward from any of the flaps, e.g., from opposing flaps. In an example, terminal tabs each extend from a flap (e.g., first flap), and the other flaps (e.g., second, third and fourth flaps) are devoid of any terminal tab extending therethrough. In an example, terminal tabs each extend from opposing flap of a pair of flaps (e.g., first and second flaps), and the other pair of flaps (e.g., third and fourth flaps) are devoid of any terminal tab extending therethrough. In an example, terminal tabs each extend from immediately adjacent flaps along the sides of the central body (e.g., first and third flaps), and the other pair of flaps (e.g., second and fourth flaps) are devoid of any terminal tab extending therethrough.

[0172] In some embodiments, folding of the extension onto the central body enhances the device. The enhancement of the device may comprise reducing its footprint, increasing its energy density, cushioning its sides, increasing the robustness of its sides, increasing its resilience to mechanical deformation, or any combination thereof. The adhesive utilized to adhere the extension (e.g., flaps and folds) with the central body, may be elastic, porous, or any combination thereof. The adhesive may be a form of a sponge. The adhesive may allow adhesion of one or more portions of the extension with (e.g., sides of, walls of) the central body, and allow for stress absorption. The stress may be mechanical stress, e.g., from external forces. The mechanical stress may be anticipated, e.g., during prescribed use of the device such as disclosed herein, during testing of the device such as disclosed herein. The adhesive may act as a cushion. Sides of the device may be bound by a cushion, e.g., in addition to the adhesive. The cushion may contact the exterior of the enclosure. The cushion may be in a form of at least one band. The cushion may surround one or more sides of the enclosure, e.g., the sides comprising the flap(s) and / or the fold(s). The cushion may be applied to the enclosure after folding of the flaps and the folds. The cushion may be reversible applied on to theAttorney Docket No. ENX-0159.WO enclosure and reversibly removed from the enclosure. The cushion may enhance the prescribed lifetime of the device and / or it ability to pass the testing such as disclosed herein such as the standardized testing.

[0173] In some embodiments, each flap of the flaps has a width. The width may be measured from the respective fold line to a free edge of the flap. The width may be at most about the height of the central portion, e.g., such that when folded, the flap does not extend beyond a height of the central portion. The height of the central portion may extend from a first enclosure portion (e.g., lid), positioned along a lateral (e.g., horizontal) plane to a second surface of the second enclosure portion (e.g., cup), positioned opposite to the first enclosure portion and (e.g., substantial) parallel thereto, with the second surface being the farthest surface of the second portion from the first portion prior to folding of the extension. The width of the flap being at most equal to the height of the central body may ensure that when the flap is folded onto the side of the central body, the flap does not extend beyond the height of the central body. The width of the flap may be selected to minimize excess material of the enclosure. The width may be selected at least in part to provide sufficient coverage of exposed edges of the enclosure. The width may be selected to provide a sufficient adhesion (e.g., adhesion strength) with the pouch, e.g., with a selected adhesive.

[0174] In some embodiments, the enclosure (e.g., pouch) comprises a structural configuration. The structural configuration may be of a central body of the enclosure. The structural configuration of the central body may include at least a base, a cover, and side wall(s). The base may be a portion of the first enclosure portion, e.g., included in the central body. The base may be parallel to the cover, the lid including the cover. The base may terminate at the fold lines of the flaps. The base may comprise a portion of the first enclosure portion that contacts the cell assembly. The enclosure may comprise a lid, e.g., being a first enclosure portion. The lid may comprise a cover portion, e.g., that is part of the lid that forms the central body of the enclosure. The enclosure may comprise a second portion that is a cup portion. The cup portion may include (a) a mating surface with the lid portion to form the extension, and (b) a recessed portion to form the wall(s) and the base of the central body of the enclosure. The cover may be (e.g., substantially) parallel to the base. The cover may be positioned opposite the base, along an axis of the pouch normal to the base (and normal to the cover). The cover and the base may be (e.g., substantially) parallel to each other. The cover may terminate at the plurality of fold lines of the extension comprising the flaps and the folds. The cover may be a section of the second enclosure portion that (e.g., at least in part through a constraint system) contacts the cell assembly. The central body may comprise a first side wall extending from the base to the cover. The central body may comprise a second side wall extending from the base to the cover. The second side wall may be opposite to the first side wall, extending along a lateral axis of the pouch. The pouch may comprise a third side wall extending from the base toAttorney Docket No. ENX-0159.WO the cover. The central body may comprise a fourth side wall extending from the base to the cover. The tab end wall may oppose the end wall, along a long axis of the pouch. The fourth side may extend from the first side wall to the second side wall. The fourth side may extend from the first side wall to the second side wall. The structural configuration may define an enclosed volume for the cell assembly and any of its associated components such as disclosed herein, e.g., the constraint system, the busbars, a busbar extension, or any combination thereof. The first side wall may have perforations for the tabs of the cell assembly to extend therethrough, e.g., through respective grommets configured to hold the interior of the enclosure sealed with the terminal tabs going through the seal.

[0175] In some embodiments, the enclosure (e.g., pouch) is configured to seal. The sealing may form the structural configuration of the enclosure. The flaps may comprise the seal. At least one side of the enclosure may be devoid of a seal.

[0176] In some embodiments, the layerwise structure of the enclosure includes the first portion extending into the second portion as one cohesive material, along a connective side of the enclosure. The connective side can be the second side of the enclosure. The extension extends from fold lines about a periphery of the central body, except for the connective side, and the extension forms a first flap, a third flap, and a fourth flap opposing the third flap, the extension is devoid of a second flap opposing the first flap. The terminal tabs may propagate through the first flap, the third flap, or the forth flap, or any combination thereof. In an example, the terminal tabs propagate through the first flap. The extension may comprise a first fold and a second fold. The first fold coupling the third flap with the first flap, and the second fold coupling the first flap with the fourth flap. The first fold and the second fold extend laterally from opposing sides of the first flap. The third flap may have one fold - the first fold. The fourth flap may have one fold - the second fold. The first fold and the second fold may be each folded along a respective fold such that they couple with the first flap and point towards each other. The first fold and the second fold may be each folded along a respective fold that is normal to the fold line of the flaps. The fold line of the flaps may be disposed in a plane, e.g., of the cover, of a plane parallel to the cover, of the base, of a plane parallel to the cover, or any combination thereof as applicable.

[0177] In some embodiments, the enclosure is sealed, e.g., by sealing the first enclosure portion with the second enclosure portion, e.g., by sealing the cup portion with the lid portion. The enclosure may be sealed along a perimeter of the central body that is otherwise unsealed. When the first enclosure portion is initially separated from the second portion, the enclosure is sealed along all sides of the central body. When the first enclosure portion extends to the second portion along a second side, the enclosure is sealed in all sides except for the second side. The enclosure may be sealed along the respective portions of the first enclosure portion and second enclosure portion that contact each other to close the enclosure. The sealing mayAttorney Docket No. ENX-0159.WO comprise pressure sealing and / or heat sealing. The sealing may create a hermetic seal. The hermetic seal may be a gas-tight seal. The gas-tight seal may hinder (e.g., prevent) ingress of external gases into an interior of the enclosure. The sealing may be performed using a hot press. The hot press may apply controlled temperature and / or pressure to sealing edges e.g., using a control system such as disclosed herein. The sealing may cause the first enclosure portion and the second enclosure portion to adhere and / or fuse together.

[0178] In some embodiments, the first and second enclosure portions may be sealed to one another to form a hermetic, or semi-hermetic seal, that encloses the cell assembly. The sealing methodology may be any sealing methodology disclosed herein. The sealing may comprise a thermoplastic welding process. The thermoplastic welding process may bring the first and second enclosure portions into contact under controlled temperature and pressure conditions, e.g., suing a control system such as disclosed herein. The first and second enclosure portions may comprise a polymeric materials such as nylon, polypropylene, polyphthalamide, or polyamide. The application of heat may cause the adjacent polymer surfaces to change phase, e.g., to soften, creep, flow, and / or melt. The phase change may allow intimate molecular-level contact and / or fusion, between the first and second enclosure portions. The sealing process may be performed along the extension of the central body. The sealing process may be performed along otherwise non-sealed portions of the extension of the central body. The extension (e.g., including peripheral edges to the central body) may create a sealed perimeter. The sealed perimeter may hinder (e.g., substantially and / or measurably prevent) ingress of reactive species and / or external contaminants. The reactive species and / or external contaminants may comprise moisture, oxygen, dust, acid, and / or other harmful environmental agents. Harmful may be to the device, to the cell assembly, to a user of the device, to the facility in which the device is disposed, or any combination thereof. Harmful to the cell assembly may comprise promoting a thermal runaway reaction, reducing functionality of the device relative to its intended specification, shorts, or any combination thereof. The integrity of the sealed bond may be important (e.g., critical) to maintaining the protective function of the multilayer enclosure material over the prescribed operation and / or lifetime of the device such as disclosed herein.

[0179] In some embodiments, the organic layers of the first and second enclosure portions fuse together during an enclosure layer sealing process. The organic layers may comprise a nylon, polyphthalamide, polypropylene, or any other organic material disclosed herein for the layerwise structure of the enclosure such as the interior facing layer of the layerwise structure. The enclosure layer sealing process may include a heat and / or pressure seal process. The organic material may be chosen in the multi-layer material for fusion characteristics and / or controlled phase change (e.g., melting) behavior, e.g., during the sealing process. When the enclosure layers comprise the organic material (e.g., polypropylene and / or polyphthalamide)Attorney Docket No. ENX-0159.WO and are subjected to controlled heat and pressure during sealing, the organic material may undergo a phase transition. The phase transition may cause the organic material to soften and / or flow. The phase change may allow intimate molecular-level contact and fusion between the first and second enclosure portions. The degree of fusion and flow may be (e.g., precisely) controlled at least in part by adjusting one or more sealing parameters, e.g., a temperature and / or pressure. The sealing temperature may be at least about 120°C (degrees Celsius), 130 °C, 140 °C, 150 °C, 160 °C, 162°C, 165°C, or 168°C. The sealing temperature may be at most about 130 °C, 140 °C, 150 °C, 160 °C, 170°C, 172°C, 175°C, or 180°C. The sealing temperature may be any value within the aforementioned values, e.g., from about 120°C to about 180°C, or from 120 °C to 170 °C. The pressure applied and duration of heat exposure may be controlled to achieve optimal results. The controlled fusion of the organic material may result in a controlled reduction in the combined thickness of the multi-layer material, e.g., at the seal location. The thickness reduction at the sealed perimeter may be at least about 5% (percent), 10%, 15%, 20%, 25%, 30%, or 50% of the original combined thickness of the first and second enclosure portions. The thickness reduction at the sealed perimeter may be at most about 50%, 45%, 40%, or 35% of the original combined thickness. The thickness reduction of the flaps may be any value within the aforementioned values, e.g., from about 5% to about 50%. This thickness reduction may occur due to the polymer material forced outward and / or inward during the fusion process. The forcing may create a localized zone of reduced cross-sectional thickness while simultaneously forging a strong molecular bond between the layers. The inherent flow characteristics of the organic material and / or its relatively low melting point, may make it ideal for achieving such controlled, predictable thickness reduction while maintaining seal integrity, e.g., while the cell assembly is disposed in the enclosure. Any parameter of the sealing disclosed herein may be controlled dynamically, e.g., during the sealing. The dynamic control may utilize one or more sensors comprising proximity sensor, temperature sensor, pressure sensor, optical sensor, or any combination thereof.

[0180] In some embodiments, the sealing temperature may be controlled based at least in part on the first enclosure portion, second enclosure portion, barrier layer, or any combination thereof. The sealing temperature may be controlled based at least in part on the layer material compositions of the first enclosure portion, second enclosure portion, barrier layer, or any combination thereof. The temperature control may promote (e.g., ensure) optimal seal formation while avoiding thermal degradation or delamination of the barrier and / or second layers. For enclosure layers comprising polypropylene in the second layer of the multi-layer materials, the sealing temperature may be selected to be below the melting point of polypropylene. The sealing temperature may remain sufficiently high to achieve fusion to seal the enclosure at the non-sealed portion of the perimeter of the central body. The sealing temperature may be adjusted such that material of the externally facing organic layer(s) (e.g.,Attorney Docket No. ENX-0159.WO nylon) does not undergo a phase transition, e.g., creeping, flowing, become tacky, undergoing a glass transition, and / or melting. The externally facing organic layer(s) may exhibit a higher melting point as compared to the organic material of the internally facing organic material containing layers. The phase transition (e.g., melting point) of the material of the externally facing layers of the layerwise structure, may be at least about 190°C (degrees Celsius), 200°C, 220°C, 230°C, 240°C, or250°C. The melting point of nylon may be at most about 220°C, 260°C, 270°C, 280°C, 290°C, or 300°C, e.g., depending on the specific material formulation. The phase transition temperature may be of any value within the aforementioned values, e.g., from about 200°C to about 300°C. In three-layer configurations incorporating a barrier layer comprising aluminum foil or high-barrier polymers such as EVOH or PVDC, the sealing process may be localized to the peripheral regions. The barrier layer may have a higher phase transition temperature (e.g., melting and / or transition point) than the first and / or second layers, e.g., such that it does not cause phase transition during the sealing process. In an example, the barrier layer is metallic, having a higher melting point that either of the organic layers among the internally facing layer and externally facing layer of the enclosure layerwise structure.

[0181] In some embodiments, the controlled thickness reduction at the seal location generates a geometric feature comprising U-shaped channel (also herein “U-channel””, e.g., a well type shape. The generated U-shaped channel, may extend around the cell assembly along the perimeter of the enclosure. The well or U-shaped channel may extend along the flaps. The U- channel may extend along the area chosen to be sealed. The well or U-channel may be formed by the fused internally facing layer and surrounding multi-layer material, e.g., during the sealing process. The compression (e.g., from a heated plate) may result in a recessed region relative to a non-compressed or sealed region. The U-channel may have a depth. The depth may correspond to the aforementioned thickness reduction. The depth of the U-channel may be at least about 5% (percent), 10%, 15%, 20%, or 25% of the original combined thickness of the two sets of layerwise structures before their sealing. The depth of the U-channel may be at most about 50%, 45%, 40%, or 35% of the original combined thickness of the two sets of layerwise structures before their sealing. The depth of the U-channel may be any value within the aforementioned values, e.g., from about 5% to about 50% of the original combined thickness of the two sets of layerwise structures before their sealing. The depth of the U- channel may provide a containment volume. A bonding agent may be strategically positioned and / or applied, within the U- channel. The application may be before, during, or after generation of the U-channel The application may be before, during, or after generation of the enclosure seal generation. The strategic positioning may provide additional mechanical reinforcement, enhanced moisture resistance, (e.g., substantially) improved structural durability of the seal, or any combination thereof. The adhesive may be disposed within the geometric confines of the U-channel (e.g., of the well). The well depth (e.g., and / orAttorney Docket No. ENX-0159.WO temperature, during the sealing process) may be designed such that the depth corresponds with a requested application amount of a bonding agent (e.g., an adhesive). The bonding agent may include a glue and / or adhesive strips. The bonding agent (e.g., adhesive) may be any of the ones disclosed herein, e.g., for sealing the enclosure. The well may offer protection for the bonding agent from external exposure. The well may create an internal pocket for the bonding agent. The pocket may contain the bonding agent. The containment may hinder (e.g., substantially and / or measurably prevent) leakage of the adhesive(s) into the cell assembly and / or outside of the enclosure. The bonding agent may be held in intimate contact with the fused layerwise surfaces on (e.g., all) sides of the channel. The configuration may promote (e.g., ensure) that the adhesive is mechanically retained within the well by the surrounding layerwise structure. The retention may hinder (e.g., substantially and / or measurably prevent) adhesive migration, exudation, loss, or any combination thereof, of adhesive properties over time such as during the prescribed use of the device and / or during the prescribed lifetime of the device. The combination of the primary sealed organic material bond and the bonding agent within the well, may create a multi-modal sealing structure. The multi-modal sealing structure may provide superior hermetic performance, enhanced mechanical strength, increased robustness, or any combination thereof, of the enclosure (e.g., pouch).

[0182] In some embodiments, the first side flap comprises a first terminal tab portion and / or a second terminal tab portion, e.g., an anode terminal tab and / or a cathode terminal tab. The first tab portion and / or second tab portion, may extend beyond the first wall of the central body, e.g., when the first side flap is folded towards the interior of the central body in a direction to contact the first side of the central body. The first terminal tab portion may extend beyond the first wall. The second terminal tab portion may extend beyond the first wall. The terminal tab portion may be configured for subsequent attachment to the flap. The attachment may provide additional securement of the terminal tab relative to the enclosure, e.g., after folding. The attachment may reduce exposure of trimmed edges of the enclosure. The attachment may provide additional sealing to corners of the enclosure.

[0183] In some embodiments, the enclosure comprises a bonding agent, e.g., an adhesive such as disclosed herein. The adhesive may constitute the cushion. The cushion may be elastic. The cushion may reversibly contract and expand. The adhesive may facilitate the folding and / or adhesion of the flaps and / or of the folds, to the central body of the enclosure. The adhesive may be applied to the enclosure, to the flaps, to the folds, or any combination thereof. The application of the adhesive may be prior to folding flaps relative to the central body. The application of the adhesive may be prior to folding the folds relative to the central body. The adhesive may be applied to a flap, a side of the central body, a fold, or any combination thereof. The adhesive may be applied to one or more of the flaps, one or more of the folds, one or more of the sides, or any combination thereof. The adhesive may be absentAttorney Docket No. ENX-0159.WO from one or more of the flaps, one or more of the folds, one or more of the sides, or any combination thereof. One or more of the sides may comprise one or more of opposing sides. One or more of the sides may comprise one or more of contacting sides. One or more of the flaps may comprise one or more of opposing flaps. One or more of the flaps may comprise one or more of immediately adjacent flaps, devoid of any flaps disposed therebetween along the perimeter of the central body, e.g., the lateral perimeter. One or more of the folds may comprise one or more of folds facing each other. The application of the adhesive may allow adhesion when the flaps and / or folds, are subsequently folded.

[0184] In some embodiments, the enclosure comprises an adhesive. The adhesive may be configured to adhere the flaps and / or folds folded onto the central body of the enclosure, e.g., to wall(s) thereof. The adhesive may comprise a pressure-sensitive adhesive, a heat-activated adhesive, a (e.g., UV) curing adhesive, or any combination thereof. The adhesive may comprise a polymer, a resin, a copolymer, a mixture thereof, a plurality of types thereof, or any combination thereof. The (e.g., pressure-sensitive) adhesive may comprise acrylic-based polymers and / or silicone-based polymers. The adhesive may be configured to provide tackiness at ambient conditions, e.g., without requiring external energy such as heat. The adhesive may be applied at a pressure of least about 2.5 pounds per square inch (psi), 5 psi, 10 psi, 15 psi, 20 psi, or 25 psi. The adhesive may be applied at a pressure of most about 25 psi, 30 psi, 35 psi, 40 psi, 45 psi, or 50 psi. The adhesive may be applied at any pressure between the aforementioned values, e.g., from about 2.5 psi to about 50 psi. The (e.g., heat- activated) adhesive may comprise a polyamide hotmelt, a polyolefin hotmelt, a polyurethane- based hotmelt, or any combination thereof. The adhesive may transition to a tacky state upon heating to a temperature of at least about 80 degrees Celsius (°C), 100 °C, or 120 °C. The adhesive may transition to a tacky state upon heating to a temperature of at most about 120 °C, 140 °C, or 160 °C. The adhesive may transition to a tacky state upon heating at a temperature between the aforementioned values, e.g., from about 100 °C to about 160 °C. The (e.g., UV curing) adhesive may comprise acrylate-based monomers and / or epoxy-based resin. The (e.g., UV) curing adhesive may be configured to cure upon exposure to electromagnetic (EM) radiation at a wavelength of at least about 250 nanometers (nm), 275 nm, 300 nm, or 325 nm. The adhesive may be configured to cure upon exposure to EM radiation at a wavelength of at most about 325 nm, 350 nm, or 375 nm. The wavelength may be any wavelength within the aforementioned values, e.g., from about 250 nm to about 325 nm. The adhesive may be configured to cure within a time of at least about 10 seconds, 20 seconds, or 30 seconds. The adhesive may be configured to cure within a time of at least about 30 seconds, 40 seconds, 50 seconds, or 60 seconds. The cure time may be any time within the aforementioned values, e.g., from about 10 seconds to about 60 seconds.Attorney Docket No. ENX-0159.WO

[0185] In some embodiments, the adhesive comprises a glue. The glue may be configured to adhere the flaps, folds, and / or central body side(s) of the enclosure. The glue may comprise an epoxy-based glue, a polyurethane-based glue, a cyanoacrylate-based glue, a hotmelt adhesive, or any combination thereof. The epoxy-based glue may comprise a resin component and a hardener component mixed in a predetermined ratio prior to application. The glue may have a pot life of at least about 5 minutes, 10 minutes, or 15 minutes. The glue may have a pot life of at most about 15 minutes, 20 minutes, 25 minutes, or 30 minutes. The pot life may be any time within the aforementioned values, e.g., from about 5 minutes to about 30 minutes. The glue may cure through moisture absorption from ambient air or substrate surfaces. The glue may provide impact resistance at a cured thickness of at least about 0.05 millimeters (mm), 0.1 mm, or 0.2 mm. The glue may provide impact resistance at a cured thickness of at most about 0.2 mm, 0.5 mm, 1 mm, or 2 mm. The cured thickness may be any value within the aforementioned values, e.g., from about 0.05 mm to about 2 mm. The glue may comprise anionic monomers that polymerize in the presence of moisture to form a bond within a time of at least about 1 second, 5 seconds, or 10 seconds. The glue may polymerize within a time of at most about 10 seconds, 20 seconds, or 30 seconds. The polymerization time may be any time within the aforementioned values, e.g, from about 1 second to about 30 seconds. The glue may provide a bond with shear strength of at least about 3 megapascals (MPa), 5 MPa, or 10 MPa. The glue may provide a bond with shear strength of at most about 10 MPa, 12 MPa, or 15 MPa. The bond strength may be any value within the aforementioned values, e.g., from about 3 MPa to about 15 MPa. The glue may provide a secondary seal to the corners of the pouch, e.g., where localized stress can occur. The glue may facilitate structural stability of the pouch, e.g., over the course of the life of the device.

[0186] In some embodiments, the glue comprises a hotmelt adhesive. The hotmelt adhesive may be moisture-curing. The hotmelt adhesive may be a mono-component reactive polyurethane. The hotmelt adhesive may be substantially and / or measurably free of added organic solvent. The hotmelt adhesive may have a (e.g., substantially) high green strength, e.g., compared to an epoxy. The hotmelt adhesive may have a short assembly time, e.g., compared to an epoxy. The hotmelt adhesive may have an (e.g., substantially) improved efficiency, capacity, yield, or any combination thereof, e.g., compared to an epoxy or doublesided tape. The hotmelt adhesive may (e.g., substantially) generate strong and tough glue lines with resistance to high and low temperature after curing and high modulus, e.g., compared to an epoxy or double-sided tape. The hotmelt adhesive may exhibit (e.g., substantially) improved adhesion to pouch nylon surfaces and / or pouch multilayer material surfaces, e.g., compared to an epoxy or double-sided tape. The hotmelt adhesive may have a viscosity at about 160°C of at least about 3 Pa.s / 160°C (Pascal-seconds at 160 degrees Celsius), 6 Pa.s / 160°C, 8 Pa.s / 160°C, or 10 Pa.s / 160°C. The hotmelt adhesive may have a viscosity at about 160°C mayAttorney Docket No. ENX-0159.WO be at most about 10 Pa.s / 160°C, 12 Pa.s / 160°C, 14 Pa.s / 160°C, or 17 Pa.s / 160°C. The hotmelt adhesive may have a viscosity may be any value within the aforementioned values, e.g., from about 3 Pa.s / 160°C to about 17 Pa.s / 160°C. The hotmelt adhesive may have a density of at least about 0.85 grams per cubic centimeter (g / cm3), 0.90 g / cm3, 0.93 g / cm3, or 0.95 g / cm3. The hotmelt adhesive density may be at most about 0.95 g / cm3, 0.97 g / cm3, 0.99 g / cm3, or 1.05 g / cm3. The hotmelt adhesive may have a density between any value within the aforementioned values, e.g., from about 0.85 g / cm3to about 1 .05 g / cm3.

[0187] In some embodiments, the adhesive (e.g., bonding agent) comprises a tape such as a double-sided tape. The double-sided tape may comprise a carrier material with adhesive layers disposed on both opposing surfaces. The carrier material may comprise foam, polymer film, paper, textile fabric, glass fiber, or any combination thereof. The foam carrier material may comprise polyethylene foam, polyurethane foam, polyvinyl chloride foam, acrylic foam, or any combination thereof. The tape (e.g., tape carrier material and / or adhesive carried by the carrier material), may constitute a cushion. The tape may comprise an elastic material, e.g., the foam may be elastic. The ta[e may comprise a material configured to reversibly contract and expand, e.g., the foam may reversibly contract and expand. The adhesive may comprise acrylic-based adhesive, silicone-based adhesive, rubber-based adhesive, any plurality of types thereof, or any combination thereof. The (e.g., double-sided) tape may have a thickness of at least about 10 micrometers (pm), 25 pm, 50 pm, 75 pm, or 100 pm. The tape may have a thickness of at most about 100 pm, 125 pm, 150 pm, or 200 pm. The thickness of the tape may be any value within the aforementioned values, e.g., from about 10 pm to about 200 pm. The tape may be pre-cut before application to any portion of the enclosure. The tape may be pre-cut to the size of the surface(s) to be adhered, e.g., such that the tape is not exposed to the external environment of the device once fully assembled. The tape may be pre-cut to the shape of the contacting surface between the flap and the side wall (or portion thereof). The tape may be pre-cut to the shape of the fold portion to be adhered to the flap or to the side wall, as applicable. The tape may be pre-cut to the shape of the contacting surface between the fold and the side wall, when they directly contact through the adhesive. The tape may be pre-cut to the shape of the contacting surface between the fold and the flap, when they directly contact through the adhesive. The tape may facilitate rapid assembly, e.g., by reducing (e.g., eliminating) the need for mixing, heating, curing, or any combination thereof. The tape may provide consistent adhesive thickness and positioning relative to the battery assembly.

[0188] In some embodiments, the enclosure may be formed at least in part by folding the flaps (also herein “corner protrusions’’ and “bat ears”). The folding may include folding the first side flap about the first fold line. The folding of the first side flap may be towards the first side wall of the central body. The folding may include folding the third side flap about the third fold line that contacts the first fold line. The folding of the third side flap may be towards the third sideAttorney Docket No. ENX-0159.WO wall of the central body that contacts the first side wall, e.g., and is angled relative to (e.g., perpendicular to) the first side wall. The extension of the enclosure may comprise the first flap and the third flap, and a remainder of the extension portion disposed therebetween, the remainder of the extension being devoid flaps, the remainder of the extension comprising a corner protrusion = a fold. In an example, a folded flap that includes at least one terminal tab, defines the location of the terminal tab(s) relative to the central body and / or to the cell assembly. The folding of the flap may comprise applying a temperature and / or pressure to the flap, against the respective wall (or wall portion) of the central body. The folding of the folds may comprise applying a temperature and / or pressure to each of the folds, against a surface. The surface can include the respective wall (or wall portion) of the central body and / or the respective flap. The compression and / or temperature, may facilitate bonding (e.g., adhesion) of the flaps and / or folds, to the central body of the enclosure. The fold lines of the flaps may be disposed in a plane, e.g., the plane of the cover of the central body. At least a portion of the fold lines of the folds, may be disposed in an angle relative to the cover, e.g., normal to the cover of the central body. The folds may comprise a crease, the crease may be angled with respect to the cover plane. The crease angle may be at least about 20 degrees (°), 30°, 40°, or 45°, with respect to the cover plane. The crease angle may be at most about 60 degrees (°), 50°, or 45°, with respect to the cover plane. The crease angle may have any angle values between reh aforementioned values, e.g., from about 20° to about 60°, or from about 40° to about 50°. The crease angle may be an acute angle relative to the cover plane. The crease angle may be different from 90° relative to the cover plane.

[0189] In some embodiments, the enclosure comprises a flap comprising at least one terminal tab, which flap is not folded, also referred to as a “non-folded tab flap” or “terrace” herein. The non-folded flap containing the terminal tab(s) may define a terrace. The non-folded flap containing the terminal tab(s), may extend outward relative to the cell assembly and / or central body of the enclosure, e.g., along a long axis of the enclosure. The terrace may be distinct from the flap that excludes a terminal tab, e.g., because it is not folded towards, the central body and / or cell assembly. The terrace may be formed during the trimming of the battery enclosure. The terminal tab of the terrace may be positioned away from it’s the central body. The terminal tab of the terrace may be disposed in the plane of the cover of the central body. The terrace may allow for a component space. The component space may be a space designed to hold one or more additional components. The additional component(s) may include circuits and / or chips, e.g., developed by the end-user of the device. The additional component(s) may comprise one or more controllers of the device, e.g., to control charging, discharging, charge carrier generation, buffering, passivation layer formation, upgrading, maintenance, and / or voltage leakage, of the cell assembly. The voltage leakage may be during storage and / or transportation of the device. The additional component(s) may comprise aAttorney Docket No. ENX-0159.WO protection circuit module. The protection circuit module may protect the device, e.g., against thermal runaway reaction, reduce short formation, mitigate conditions for metal deposition (e.g., dendrite formation), and / or otherwise increase its safety. The open terrace may allow placement and / or attachment of the other components such as the protection circuit module. The additional component(s) (e.g., protection circuit module) may comprise a flexible printed circuit board. The additional component(s) (e.g., protection circuit module) may be configured to monitor electrical parameters of the energy manipulation device. The open terrace may increase overall dimensions of the energy manipulation device, e.g., as compared to a device in which all the extension to the central body (e.g., all the flaps and folds) are folded. The terrace may comprise exposed edges resulting from the trimming and / or folding, e.g., operations. In an example, reducing the footprint of the open terrace (e.g., by folding it towards the central body), will increase the energy density of the device, and reduce its footprint. In the case of a folded extension devoid of an open terrace, the additional component(s) may contact a folded flap side, contact a side of the enclosure devoid of a folded flap (e.g., top, or bottom of the enclosure), or any combination thereof.

[0190] In some embodiments, the flap laterally extends to folds constituting corner protrusions. The flap laterally may extend to folds along the long axis (e.g., lateral axis) of the flap. The corner protrusions (also referred to herein as “folds”) may be formed from the extension as a consequence of folding of the plurality of flaps. The folds may be excess material of the extension of the enclosure. The folds may extend laterally to the one or more sides of the flaps, and the lateral terminals (e.g., end edges) of the flaps. A fold (e.g., corner protrusion) may be formed at an intersection of immediately adjacent flaps devoid of a flap disposed therebetween. A fold may be formed when immediately adjacent flaps attempt to contact each other at their lateral sides, e.g., and at a corner of contacting central body sides. A fold may be formed from a remainder of extension disposed between immediately adjacent flaps. The folds may be formed from a deformation of the extension to allow flaps to contact the side wall(s) of the central body, e.g., during subsequent folding of the flaps along the fold lines. The geometry of the folds (e.g., corner protrusions) may result at least in part from the geometry of the sealing and trimming operations. The geometry of a fold may comprise triangular portion, trapezoidal portion, irregular portion, truncated triangle, or any combination thereof. Priorto being attached onto the central body, the fold (=corner protrusion) may extend outwards from the wall intersections, e.g., along the lateral and / or longitudinal axis of the cell assembly. Prior to being attached onto the central body, the fold (=corner protrusion) may extend outwards from the wall intersections, e.g., along the lateral and / or longitudinal axis of the central body.

[0191] In some embodiments, the enclosure comprises folded corner protrusions, e.g., folded folds. The folds may be configured to be folded in a side-wall configuration. The side-wall configuration may comprise folding the corner protrusions along the first side wall and / or theAttorney Docket No. ENX-0159.WO second side wall contacting the second side wall opposing the first side wall. The side-wall configuration may comprise corner protrusions emanating from the lateral ends of a flap adhering to a respective wall, e.g., as disclosed herein. The corner protrusions emanating from the lateral ends of a flap, may be folded along the lateral axis of the flap and towards each other. The corner protrusions may be referred to herein as a “bat ears” or “folds”. Folding of the corner protrusion may reduce its footprint, e.g., and overall reduce the footprint of the enclosure - and by this increase the device’s energy density. The folding of the bat ears may reduce the volume (e.g., footprint) of the device, e.g., and thereby increase its energy density.

[0192] In some embodiments, the flap has a width. The width of the flap (e.g., first flap and / or opposing second flap) may extend beyond a fold line between the central body and the extension of which it is a portion of. The width of the flap may correspond to the side of the central body of the enclosure to which it adheres to. The width of the flap may be defined by trimming. The width of the flap may correspond to the side of the central body of the enclosure to which it adheres to (e.g., Z axis), such as disclosed herein. In an example, the width of the flap is at least about 5 millimeters, 10 millimeters, 15 millimeters, or 20 millimeters. In an example, the width of the flap may be at most about 20 millimeters, 32.5 millimeters, 45 millimeters, or 60 millimeters. In an example, the width of the flap may be any value within the aforementioned values, e.g., from about 5 millimeters to about 60 millimeters. The FLSs of the fold may correspond to the FLS of the enclosure such as disclosed herein. The flap may have a length. The length of the flap may extend along the fold line of the flap with the central body. The length of the flap may correspond to a width of the cell assembly and / or central body (e.g., X axis), along the lateral axis of the pouch. The length of the flap may correspond to a length of the cell assembly and / or central body (e.g., Y axis), along the stacking axis of the cell assembly. At least one FLS of the flap (e.g., width and / or length) may be selected based at least in part on the requested volume of the energy manipulation device, e.g., of the battery. At least one FLS of the flap (e.g., width and / or length) may be selected based at least in part on a requested volume of the cavity of the target device into which the energy manipulation device is destined to be located at, e.g., within jurisdictional and / or industrial tolerances such as disclosed herein.

[0193] In some embodiments, the energy manipulation device comprises bent terminal tabs. The bended terminal tabs may be formed by performing a first bend of terminal tab(s) extending from the cell assembly, e.g., along a respective fold line of the flap in which the terminal tab(s) is disposed. The terminal tabs may comprise an anode terminal tab, a cathode terminal tab, or a combination thereof. The first bending of the terminal tabs may be performed at and / or near the flap fold line. The first bending operation may generate a first bend in the terminal tab. The first bend of the terminal tab may be positioned at a location where the electrode tab protrudes from the central body, e.g., and from the cell assembly. The adhesive may be applied to theAttorney Docket No. ENX-0159.WO terminal tab prior to performing the first bending operation to generate the first bend. The adhesive may facilitate adhesion during and / or after the folding operation of the flap, e.g., and of any terminal tab disposed therein. The first bending operation of the terminal tabs may comprise bending the terminal tab from a first axis (e.g., substantially) parallel to, or at, the cover plane of the enclosure. The first bending operation may transition the terminal tab from an extended configuration to an angled (e.g., upright) configuration. The extended configuration may be the pre-fold structure. Such extended configuration may remain in the case of an open terrace. The angled (e.g., upright) configuration of the first bend may be about a 90° from the extended configuration. The first bend of the terminal tab may comprise a bend angle. The first bend angle may be at least about 85°, 87.5°, or 90°. The first bend angle may be at most about 90°, 92.5°, or 95°. The first bend angle may be any value within the aforementioned values, e.g., from about 85° to about 95°. The first bending operation of the terminal tab may be performed (e.g., substantially) simultaneously with folding the flap in which it is disposed, e.g., as a consequence of the flap folding. After the first bending operation of the terminal tab(s), the terminal tab(s) may be positioned (e.g., substantially) angled (e.g., perpendicular) relative to the cover of the enclosure’s central body.

[0194] In some embodiments, the first bending operation of the terminal tabs comprises a bend having a radius at the tab bent location. The bend radius may facilitate mechanical reliability and / or (e.g., substantially) reduce stress concentration in the terminal tabs. The bend radius at the first bending location may be at least about 0.10 millimeters (mm), 0.13 mm, or 0.15 mm. The bend radius at the first bending location may be at most about 0.15 mm, 0.17 mm, or 0.20 mm. The bend radius may be any value within the aforementioned values, e.g., from about 0. 10 mm to about 0.20 mm. In an example, the bend radius at the first bending location is about 0.15 mm.

[0195] In some embodiments, the bent terminal tab(s) is bent due to a second bending operation. The second bending operation of the terminal tab may comprise performing a second bending operation at a distal location of the terminal tab away from the cell assembly and / or away from the first bending location. The second bending operation may be performed after the first bending operation of the terminal tab(s). The distal location may be positioned at a height (e.g., substantially) at, above, or below the height of the cell assembly and / or central body of the enclosure. The location of the height may be determined by design considerations, e.g., for an end user device - a target device having an accepting cavity for the energy manipulation device. The second bend may comprise bending the terminal tab(s) from a first angular configuration with respect to the cover plane, to a second angular configuration with respect to the cover plane. The first bent angle can be different in sign and / or in absolute value, from the second bent angle. The first bent angle can be an acute angle, and the second bent angle can be an obtuse angle, (e.g., substantially) a right angle, an acute angle or (e.g.,Attorney Docket No. ENX-0159.WO substantially) a zero angle. The first bent angle can be a right angle, and the second bent angle can be an obtuse angle, (e.g., substantially) a right angle, an acute angle or (e.g., substantially) a zero angle. The first bent angle can be an obtuse angle, and the second bent angle can be an obtuse angle, (e.g., substantially) a right angle, an acute angle or (e.g., substantially) a zero angle. The second bend may comprise bending the terminal tab(s) from an upright configuration to a (e.g., substantially) planar configuration. The planar configuration may position the terminal tab(s) (e.g., substantially) parallel to a cover of the central body and / or to the base of the central body. The second bend of the terminal tab(s) may comprise the second bend angle. The second bend angle may be measured from an axis normal to the cover of the central body. The second bend angle may be at least about 85°, 87.5°, or 90°, relative to an axis normal to the cover of the central body. The second bend angle may be at most about 90°, 92.5°, or 95°, relative to an axis normal to the cover of the central body. The second bend angle may be any value within the aforementioned values, e.g., from about 85° to about 95°, relative to an axis normal to the cover of the central body. After the second bend, distal portion of the terminal tab may lie substantially planar (e.g., flat) on, or parallel to, a plane of the cover of the central body. The configuration of the terminal tab may facilitate positioning and / or coupling (e.g., welding) of the terminal tab to coupling pads to additional component(s) such as disclosed herein, e.g., a protection circuit module. An adhesive may be applied between the terminal tab(s) and adjacent surface(s) of the additional component(s), e.g., to secure the electrode tabs in the planar configuration. The additional components may be referred to as “accessories.” An adhesive may be applied between the enclosure and adjacent surface(s) of the cavity of the target device, e.g., to secure the energy manipulation device (e.g., battery) with the target device, e.g., in a requested configuration.

[0196] In some embodiments, the second bend of the terminal tab comprises a bend having a radius at the distal tab bend location. The bend radius may facilitate mechanical reliability and / or reduce stress concentration in the electrode tab at the planar portion. The radius at the second bend may be at least about 0.10 millimeters (mm), 0.13 mm, or 0.15 mm. The radius at the second bend may be at most about 0.15 mm, 0.17 mm, or 0.20 mm. The bend radius may be any value between any of the aforementioned values, e.g., from about 0.10 mm to about 0.20 mm. The radius at the second bend may be about 0.15 mm.

[0197] In some embodiments, a flap comprises a second trimming. The second trimming of the flap may allow second bending of the electrode tab(s) to be positioned (e.g., substantially) along the flap and aligned with respect to the flap. In an example, two terminal tabs may be disposed such that the pair of terminal tabs is centered about the middle of the flap. The second trimming of the flap through which terminal tab(s) emerge, may allow the second bend of the electrode tabs to be positioned at a location between the base and the cover of the central body, along a wall of the central body. The trimming operation may be performed during theAttorney Docket No. ENX-0159.WO formation of the extension of the enclosure and / or sealing of the enclosure portions (e.g., lid and cup). The trimming may remove excess material from the flap through which the terminal tab emerges, e.g., to achieve a requested configuration. The trimming operation may reduce an overall width and / or length of the associated flap. Positioning of the second bend (e.g., substantially) at the middle of the central body’s wall, may facilitate symmetric distribution of the bended terminal tab(s). The symmetric distribution may improve balance and / or stability of the bent structure. The positioning of the second bend (e.g., substantially) at the middle of the central body’s wall, may allow access to the respective terminal tab, e.g., for subsequent coupling (e.g., welding) operations such as to the accessories and / or to the cavity of the target device. The terminal tab, if emerging alone from a tab, may be positioned (e.g., substantially) equidistant from opposing lateral edges (e.g., side edges) of the central body’s wall. The pair of terminal tabs emerging from the same flap, may be positioned (e.g., substantially) equidistant from opposing lateral edges (e.g., side edges) of the central body’s wall. The terminal tab, orthe pair of terminal tabs (when emerging from the same flap), may be positioned at a location that (e.g., substantially) corresponds to the center axis of the central body at a plane parallel to the cover of the central body, e.g., and along its width and / or length dimension, as applicable. The trimming operation may be calibrated such that, after the first and second bends of the terminal tab are performed, the pair terminal tabs emerging from the same flap lie (e.g., substantially) planar (e.g., flat) parallel to the cover of the central body, at a location (e.g., substantially) aligned with the geometric center of the respective wall and / or flap from which they emerge. The trimming operation may be calibrated such that, after the first and second bends are performed, the lone terminal tab emerging from a flap lies (e.g., substantially) planar (e.g., flat) parallel to the cover of the central body, at a location (e.g., substantially) aligned with the geometric center of the respective wall and / or flap from which it emerges. The trimmed flap configuration may increase the accuracy of positioning of the terminal tab(s) relative to coupling (e.g., welding) pads on a protection circuit module positioned on the folded terrace.

[0198] In some embodiments, an adhesive (e.g., a bonding agent) is applied to at least one surface of the enclosure. The at least one surface may comprise (i) the wall of the central body, e.g., destined to contact any other portion of the enclosure (e.g., the flap and / or the fold(s)) (ii) at least a portion the flap designed to contact any other portion of the enclosure (e.g., the wall of the central body and / or the fold(s)), (iii) at least a portion of the fold destined to contact any other portion of the enclosure (e.g., the wall of the central body and / or the flap), or (iv) any combination thereof. The adhesive may be applied prior to, or during, folding the flap. The adhesive may be applied prior to, or during, folding the corner protrusion (a.k.a. the fold). The application of the adhesive may at least in part allow adhesion of the folded flap to the central body and / or to the folds, respectively and / or as applicable. The application of the adhesive may allow adhesion of the corner protrusions and the central body and / or to the flap,Attorney Docket No. ENX-0159.WO respectively and / or as applicable. The adhesive may comprise a glue, a tape, or any combination thereof. The glue may comprise an epoxy-based glue, a polyurethane-based glue, a cyanoacrylate-based glue, any combination thereof, or any other glue disclosed herein. The glue may comprise a hotmelt adhesive. The hotmelt adhesive may comprise a polyurethane hotmelt. The adhesive may comprise a tape such as a single sided tape, or a double-sided tape. The double-sided tape may comprise a carrier material having layer(s) of the adhesive disposed on one or both opposing surfaces. In some embodiments, the adhesive is configured to harden, mature, and / or otherwise cure, at ambient temperature, e.g., room temperature.

[0199] In some embodiments, the adhesive comprises a heat-activated adhesive. The heat- activated adhesive may comprise a hotmelt adhesive. The hotmelt adhesive may be applied after it underwent a phase transition. The phase transition may comprise fluidization, liquification, glass transition, forming a creeping material, and / or melting. The phase transition may be configured to activate binding sites in the adhesive, e.g., to allow the adhesive to initiate adhesion such as become tacky. The requested phase transition may be achieved at least in part by heating the adhesive to a temperature above ambient temperature and below a harmful temperature. The harmful (e.g., adverse effects) can be to the energy manipulation device, to its user, to a facility in which the device is disposed, or any combination thereof. The harmful temperature may cause initiation of a thermal runaway reaction, accelerate shorts in the cell assembly, cause one or more layers of the enclosure (e.g., pouch) to undergo a phase transition, or any combination thereof. The one or more layers may include the layer facing the interior of the enclosure. The one or more layers may be other than the layer facing the interior of the enclosure. The requested phase transition may be achieved at least in part by heating the adhesive to a temperature of at least about 50 degrees Celsius (°C), 60°C, 80 °C, or 120 °C. The molten state may be achieved by heating the adhesive to a temperature of at most about 100°C, 120 °C, 140 °C, or 160 °C. The temperature may be any value within the aforementioned values, e.g., from about 80 °C to about 160 °C, or from about 50°C to about 100°C. Upon cooling, the hotmelt adhesive may harden. The hardening may comprise stiffening, solidification, (e.g., substantial and / or measurable) cessation of flowability, or any combination thereof. The hardening may occur within a time period of at least about 10 seconds (sec), 20 sec, or 30 sec. The hardening may occur within a time period of most about 30 sec, 40 sec, 50 sec, or 60 sec. The hardening time may be any time within the aforementioned values, e.g., from about 10 sec to about 60 sec. The adhesive may comprise ethylene-vinyl acetate, polyamide, polyolefin, polyurethane, or any combination thereof. The adhesive may comprise any hotmelt adhesive disclosed herein. The adhesive may be applied in a rectangular pattern, a bead pattern, a spiral pattern, a zigzag pattern, or any combination thereof. The adhesive may be applied, e.g., in any pattern shown in Fig. 2, 251 , 252, 253, 254, 271 a, 271 b, 272a, 272b, 273a, 273b, or any combination thereof.Attorney Docket No. ENX-0159.WO

[0200] In some embodiments, the adhesive comprises a curing adhesive. The curing adhesive may be applied in a fluid state. The fluid state may comprise liquified state, glass state (e.g., following a glass transition), creeping state, and / or molten state. The curing adhesive may cure upon exposure to electromagnetic radiation, e.g., visible light, ultraviolet light, infrared light, or any combination thereof. The electromagnetic radiation may have a wavelength of at least about 250 nanometers (nm), 275 nm, 300 nm, or 325 nm. The ultraviolet radiation may have a wavelength of at most about 325 nm, 350 nm, or 375 nm. The ultraviolet radiation may be any wavelength within the aforementioned values, e.g., from about 250 nm to about 325 nm. The curing adhesive may be configured to cure within a time of at least about 10 seconds (sec), 20 sec, or 30 sec. The UV-curing adhesive may be configured to cure within a time of at least about 30 sec, 40 sec, 50 seconds, or 60 sec. The cure time may be any time within the aforementioned values, e.g., from about 10 sec to about 60 sec. The curing adhesive may comprise acrylate-based polymers, epoxy-based polymers, or any combination thereof. The curing adhesive may provide high bond strength with minimal thermal exposure to the battery enclosure. The curing may be by exposure to a chemical environment. The chemical environment may comprise one or more reactive agents. The reactive agent may comprise acid, base, oxygen, carbon dioxide, hydrogen sulfide, or water. The reactive agents may be present in an ambient environment external to the enclosure. The reactive agents may comprise oxidating agents.

[0201] In some embodiments, the flap is compressed against the central body wall. The compression may be performed after folding the flap about a fold line. The compression may be performed after, or during, application of the adhesive to the enclosure, e.g., as disclosed herein. The compression may be performed after folding the corner protrusion onto one or more flap(s) of the enclosure, e.g., the flap across which the compression is performed. The compression may comprise applying a compressive force across the respective wall of the central body, the surface of the flap across which the compression is executed, the bat ear fold (e.g., corner protrusions) across which the compression is executed, or any combination thereof. The compressive force may be (e.g., substantially) uniform across the flap, the fold, and / or the wall, on which the compression is executed. The compressive force may be (e.g., substantially) equal to a pressure of at least about 2.5 pounds per square inch (psi), 5 psi, 10 psi, or 20 psi. The compressive force may be equal to a pressure of at most about 20 psi, 35 psi, or 50 psi. The pressure may be any value within the aforementioned values, e.g., from about 2.5 psi to about 50 psi. The pressure applied to the tab end flap may be lower than the pressure applied to the side flaps. The lower pressure may reduce stress on the electrode tabs extending from the second end wall. The lower pressure may be a force of at least about 2 psi, 10 psi, or 15 psi. The lower pressure may be a force of at most about 15 psi, 27.5 psi, or 40 psi. The lower pressure may be any value within the aforementioned values, e.g., from aboutAttorney Docket No. ENX-0159.WO2 psi to about 40 psi. The pressure applied to the tab end flap may be higher than the pressure applied to the side flaps. The higher pressure may promote adhesion and / or account for a smaller flap area connection, e.g., due to the electrode tabs, relative to the end flap. The compressive force may be equal to a pressure of at least about 5 psi, 10 psi, or 15 psi. The compressive force may be equal to a pressure of at most about 15 psi, 27.5 psi, 40 psi, or 60 psi. The pressure may be any value within the aforementioned values, e.g., from about 3 psi to about 40 psi. In some embodiments, the compression is performed for a first compression time. The first compression time may be at least about 10 seconds (sec), 20 sec, or 30 sec. The first compression time may be at most about 30 sec, 45 sec, or 60 sec. The first compression time may be any value within the aforementioned values, e.g., from about 10 sec to about 60 sec. The first compression time may be selected to allow the adhesive to achieve a requested adhesion strength. The first compression time may be selected based at least in part on the type of adhesive used. The first compression time may be selected based at least in part on the temperature applied during compression.

[0202] In some embodiments, the compression is performed while the flap is heated, the flap being the one across which the compression is executed. The heating may be to a first temperature. The first temperature may be at least about 50 degrees Celsius (°C), 75 °C, 100 °C, or 125 °C. The first temperature may be at most about 125 °C, 137.5 °C, or 150 °C. The first temperature may be any value within the aforementioned values, e.g., from about 50 °C to about 150 °C. The heating may facilitate activation of the bonding agent, e.g., a heat activated bonding agent. The heating may increase the tackiness of the adhesive. The increased tackiness may improve adhesion between the tab end flap and / or the bat ear fold, to the pouch. The heating may be applied using heated platens, heated rollers, infrared heaters, or any combination thereof. The heating may be controlled to avoid damage to the pouch, the tab end flap, the corner protrusions, the tabs, the cell assembly, or any combination thereof. In some embodiments, the compressing of the end flap is performed for a second compression time. The second compression time may be at least about 10 seconds (sec), 20 sec, or 30 sec. The second compression time may be at most about 30 sec, 45 sec, or 60 sec. The second compression time may be any value within the aforementioned values, e.g., from about 10 sec to about 60 sec. The second compression time may be the same as the first compression time. The second compression time may be different from the first compression time. The second compression time may be selected based at least in part on the bonding agent used for the wall, for the flap and / or for the fold.

[0203] In some embodiments, the compressing of the end flap is performed while the end flap is heated. The heating may be to a second temperature. The second temperature may be at least about 50 degrees Celsius (°C), 75 °C, 100 °C, or 125 °C. The second temperature may be at most about 125 °C, 137.5 °C, or 150 °C. The second temperature may be any valueAttorney Docket No. ENX-0159.WO within the aforementioned values, e.g., from about 50 °C to about 150 °C. The second temperature may be the same as the first temperature. The second temperature may be different from the first temperature. The second temperature may be selected based at least in part on the adhesive used for the end flap. The second temperature may promote uniformity of the adhesive.

[0204] In some embodiments, a compression fixture is used to apply pressure towards the walls of the central body. The pressure may be applied to the flaps and / or to the folds. The compression fixture may comprise platens. The platens may be planar (e.g., flat) surfaces configured to apply (e.g., substantially) uniform pressure across the wall. The platens may be heated. The platens may comprise metal, ceramic, composite materials, or any combination thereof. The compression fixture may comprise fasteners such as clamps. The fasteners may be configured to hold the enclosure in position at least during the compression operation. The compression system (e.g., comprising fixtures such as the platen) may comprise presses. The presses may be hydraulic presses, pneumatic presses, mechanical presses, electrical presses, or any combination thereof. The presses may be configured to apply controlled force to the wall(s). The compression system (e.g., any component thereof) may be controlled, e.g., using a control system such as disclosed herein. The pressure and / or temperature of the compression system (e.g., any respective component thereof) may be controlled, e.g, by the control system. The control system may control the position of the compression component, temperature and / or pressure. The control may be before, and / or during operation of the compression components on the enclosure section. The control may be dynamic, e.g., in real time during operation of the compression system.

[0205] In some embodiments, the compression system is controlled. The control may comprise temperature, pressure, and positional (e.g., proximity) control. The control may allow controlled heating of the adhesive, wall, flap, fold, or any combination thereof, at a time associated with the compression. The control may allow controlled compression of the adhesive, wall, flap, fold, or any combination thereof, at a time associated with the compression. The control may allow controlled positioning of the adhesive, wall, flap, fold, or any combination thereof, at a time associated with the compression. The time associated with the compression may be before, during, and / or after their compression. The control may utilize one or more sensors. The one or more sensors may comprise thermocouples, resistance temperature detectors, thermistors, pressure sensors, proximity sensors, electromagnetic sensors, any other applicable sensors disclosed herein, or any combination thereof. The electromagnetic sensor may comprise a camera (e.g., charged coupled device (CCD) camera). The camera may be a stills and / or a video camera. The camera may provide data for image processing, e.g., to be processed by a processor. The temperature control may rely at least in part on proximity and / or location sensors. The control (e.g., temperature and / or pressureAttorney Docket No. ENX-0159.WO control) may rely at least in part on pressure sensors. The control may maintain the first temperature during compression onto the wall(s) of the enclosure. The control may maintain the second temperature during the compression onto the wall(s) of the enclosure. The controlled compression system may allow for multi-stage compression processes. The multistage compression processes may apply different temperatures at different stages. The multistage compression processes may apply different pressures at different stages. The different temperature and / or pressures may be related by a relationship reduced to a mathematical scheme such as a function, e.g., a series. The different temperature and / or pressures may be applied intermittently onto the wall(s), e.g., at pulses. The multistage compression may rely on feedback control scheme, e.g., as disclosed herein.

[0206] In some embodiments, the compression system is configured to maintain pressure for a predetermined duration. The predetermined duration may correspond to the first compression time for the side walls. The predetermined duration may correspond to the second compression time for side wall. The maintenance of pressure may allow the adhesive to cure, to set, to achieve sufficient adhesion strength, to harden, to (e.g., substantially and / or measurably) cease from flowing, or any combination thereof. The compression system may be programmable, e.g., using a code such as part of a software. The programmable compression system may automatically control pressure, temperature, position, duration, or any combination thereof. The programmable compression system may allow for consistent, repeatable, robust, folding and / or bonding operations, across multiple cell assembly architectures such as disclosed herein.

[0207] In some embodiments, the method comprises one or more operation to minimize footprint of the enclosure. The one or more operations may comprise (a) disposing a cell assembly into a first portion of the enclosure (e.g., into a cup portion) such that the terminal tabs of the cell assembly extend from the cell assembly to outside of the first portion of the enclosure, (b) closing the first portion with a second portion (e.g., lid) such that the terminal tabs of the cell assembly extend from the cell assembly to outside of the second portion of the enclosure, (c) sealing the enclosure the terminal tabs of the cell assembly extend from the cell assembly to outside of the enclosure to generate a central body and an extension extending from the central body, the central body having a base opposing a cover, (d) optionally trimming the enclosure (e.g., trimming the extension), (e) optionally applying an adhesive, (f) folding the flaps towards the central body in direction(s) having a vectorial component normal to the cover, (g) folding the folds towards the central body, (h) folding distal ends of the terminal tabs, or (i) any combination thereof, e.g., performed in any applicable order. The adhesive may be applied to the wall(s) to the fold(s), to the flap(s), or any combination thereof. The folds may be folded toward the side wall before, or after, folding of the flaps. The folds can be external to the flapsAttorney Docket No. ENX-0159.WO relative to the central body. The flaps can be external to the fold relative to the central body. In an example, the folds are external to the flaps relative to the central body.

[0208] In some embodiments, a method comprises folding a first terminal tab and a terminal second tab about the central body of the enclosure, e.g., as disclosed herein. The folding may be performed after a flap through which they propagate, is folded about its respective fold line. The flap may be in contact with the respective wall of the central body.

[0209] In some embodiments, an adhesive is applied to allow attachment of the tabs to the end flap. The bonding agent may be applied after the end flap is folded into contact with the pouch. The bonding agent may be applied to the second surface of the end flap. The adhesive may be applied to the first surface of the first tab, the first surface of the second tab, or both. The bonding agent may comprise an adhesive strip, a liquid adhesive, an epoxy, a resin, or any combination thereof. The application of the bonding agent may be performed using a manual applicator, an automated dispenser, or both. The application may apply the bonding agent in a pattern configured to maximize adhesion strength while minimizing bonding agent usage. The adhesive may be applied to a surface until its edges, or until a gap from the edge. The gap from the edge may create a frame (e.g., substantially) devoid of adhesive. The gap (e.g., and framing) is configured such that when the adhered components contact, and the adhesive hardens, the adhesive reaches the edge of the component onto which it is applied. For example, the adhesive may be applied on a flap and reach a framing devoid of adhesive, the framing reaching the edge of the flap. When that flap contacts its respective sidewall, that adhesive may fill the framing to reach the edge of the flap.

[0210] In some embodiments, the terminal tab(s) are disposed between folds that point to each other. The folds have a thickness, which may be greater or (e.g., substantially and / or measurably) equal to the thickness of the terminal tab(s). In this way, the folds can form a physical protection for the terminal tab(s) disposed therebetween, e.g., from inadvertent friction and / or compression applied towards the terminal tab(s).

[0211] In some embodiments, the terminal tab has a tab width extending in a lateral direction, e.g., along a fold line through which the tab propagates. The tab width may be at least about 5 millimeters (mm), 8 mm, 10 mm, 12 mm, or 15 mm. The tab width may be at most about 25 mm, 20 mm, or 18 mm. The tab width may be selected to provide sufficient coverage of the edge of the first end wall, and / or to facilitate efficient electrical current exchange relative to the cell assembly. The terminal tabs may have a tab width (e.g., substantially and / or measurably) equal to each other. The tab widths of the two terminal tabs (e.g., anode and cathode terminal tabs) may differ by at most about 5 mm, 3 mm, 2 mm, 1 mm or 0.5.

[0212] In some embodiments, the first tab has a tab length. The tab length may extend (e.g., when fully stretched and disposed at or parallel to the enclosure base) in a direction perpendicular to a fold line through which the tab propagates. The tab length may be at leastAttorney Docket No. ENX-0159.WO about 3 millimeters (mm), 5 mm, 8 mm, or 10 mm. The tab length may be at most about 20 mm, 15 mm, or 12 mm. The tab length may be selected based at least in part on a width flap from which it propagates, the height of the respective wall of the central body, and / or to facilitate efficient electrical current exchange relative to the cell assembly. The tab length may be selected to allow it to extend across the flap when folded, and optionally reach the cover of the central body. The terminal tabs may have a tab length (e.g., substantially and / or measurably) equal to each other. The tab length of the two terminal tabs (e.g., anode and cathode terminal tabs) may differ by at most about 5 mm, 3 mm, 2 mm, 1 mm or 0.5.

[0213] In some embodiments, a method comprises compressing the terminal tab(s) against a flap from which it / they emerge, e.g., against the first flap. The compression may be performed during and / or after folding the tab(s) towards that flap from which it / they emerge. The compression may apply a compressive force to the tab from which it / they emerge. The compressive force may be applied towards the wall of the central body onto which the flap is destined to attach. The compressive force may allow bonding of the terminal tab(s) to the flap from which it / they emerge. The compressive force may be (e.g., substantially and / or measurably) uniform across the terminal tab(s). The compressive force may be concentrated at locations where the adhesive is applied to the terminal tabs. The compression may be performed (e.g., substantially) simultaneously with compressing the flap against the respective wall.

[0214] In some embodiments, the compression of the terminal tabs is performed for a tab compression time. The tab compression time may be at least about 10 seconds (sec), 15 sec, 20 sec, or 25 sec. The tab compression time may be at most about 60 sec, 50 sec, 40 sec, or 30 sec. The tab compression time may be a first tab compression time. The first tab compression time may be (e.g., substantially and / or measurably) same as a second tab compression time. The first tab compression time may be different from the second compression time. The tab compression time may be selected based at least in part on the adhesive used for the terminal tabs. The tab compression time may be selected to promote (e.g., ensure) sufficient curing of the bonding agent, e.g., to harden and / or cease its creeping. The first tab compression time may overlap with the second tab compression time for process efficiency.

[0215] In some embodiments, the compressing of the tabs is performed while the terminal tab(s) are heated. The heating may be to a tab temperature. The tab temperature may be at least about 50 degrees Celsius (°C), 70 °C, 90 °C, or 110 °C. The tab temperature may be at most about 100 °C, 150 °C, 140 °C, or 130 °C. The tab temperature may be a first tab temperature. The first tab temperature may be (e.g., substantially) the same as the second temperature. The tab temperature may be different from the second temperature. The tab temperature may be controlled independently from the temperature applied to other portionsAttorney Docket No. ENX-0159.WO of the battery enclosure, e.g., using a control system such as disclosed herein. The independent temperature control may allow for optimization of bonding conditions for different bonding agents used on different flaps, different folds, different walls, different portion types of the enclosure, or any combination thereof. The different portion types of the enclosure comprise folds, flaps, walls, or any combination thereof.

[0216] In some embodiments, the energy manipulation device (e.g., battery) is configured to electrically, chemically and / or physically, insulate the terminal tabs. The terminal tabs insulation may comprise a grommet. The grommet may be positioned at the tab end. The terminal tabs’ insulation may comprise a grommet for each terminal tab. Each grommet may surround a respective terminal tab. The terminal tabs may comprise anode tab, cathode tab, or any combination thereof. The terminal tab may have a thickness of at least about 0.05 millimeters (mm), 0.08 mm, or 0.10 mm. The terminal tabs may have a thickness of at most about 0.10 mm, 0.12 mm, 0.15 mm or 0.20 mm. The terminal tab thickness may be any value within the aforementioned values, e.g., from about 0.05 mm to about 0.20 mm. The grommet may be configured to accommodate the terminal tab thickness. The grommet may be applied to the terminal tab such that it compresses onto the terminal tab, e.g., to allow a hermetic seal. The hermetic seal may be configured as a fluid tight seal such as a gas tight and / or liquid tight seal. The hermetic seal may be configured as a solid tight seal such as a powder seal, e.g, dust seal. The grommet may comprise an electrically insulating material. The electrically insulating material may comprise silicone, rubber, polyurethane, thermoplastic elastomer, any plurality of types thereof, or any combination thereof. The grommet may provide insulation between the terminal tabs and the battery enclosure. The grommet may provide strain relief for the terminal tabs. The strain relief may (e.g., substantially) reduce mechanical stress on the terminal tabs during bending, handling, or any combination thereof.

[0217] In some embodiments, the flap may be configured in relation to the grommets. The grommet may be disposed in an extension of the enclosure from the central body. At least a portion of the grommet may be disposed in a flap of the extension. The grommet may initiate after a fold line of that flap. The grommet may extend past an edge of the extension, e.g., and an end of the flap with which it is associated. The flap (e.g., first and / or second flap) may be folded such that the grommet disposed therein is initiated after the folding line about which the flap is folded. The grommet may be disposed in a flap that is folded onto and attached to a wall of the enclosure. That flap may be designed at least in part by considering the dimensions and / or positioning of its associated grommet. That grommet may be designed at least in part by considering dimensions and / or positioning of its associated flap. The grommet may be designed at least in part by considering the dimensions and / or positioning of its associated wall. The grommet may extend past an edge of the extension of the enclosure. Bending of the distal end of the terminal tab, may take place past the grommets. An adhesive may be appliedAttorney Docket No. ENX-0159.WO around the grommets. The bonding agent may be applied during the folding of the electrode tabs and / or tab end flap. The adhesive may be applied to the terminal tab disposed in the grommet. The bonding agent application may reinforce the terminal tab, its associated flap, its associated grommet, or any combination thereof.

[0218] In some embodiments, the corner protrusions associated with a flap may be configured in relation to the grommet disposed in the flap. The corner protrusions associated with a flap may extend towards each other such that they avoid contacting the grommet. The corner protrusions may reach the grommet(s), along the lateral axis of the flap, e.g., and during folding of the corner protrusions (a.k.a., folds) to point towards each other. The corner protrusions may be trimmed to (e.g., substantially) reduce overlapping with their grommet(s). The trimming operation may hinder (e.g., prevent) the folds from interfering with the grommets. The prevention of interference may avoid increasing the overall volume in the grommet region, e.g., avoid reducing the energy density of the device. The grommet region may experience additional volume increase, e.g., due to the associated grommet volume, the folded terminal tab(s), the flap, and / or the folds. Trimming of the folds may change a shape of the folds, e.g., to generate a truncated shape such as a truncated triangle. The modified shape may comprise a more tapered profile, a cut-back profile, an angled profile, truncated profile, or any combination thereof. A gap may be defined between the grommet and its immediately adjacent corner protrusion (a.k.a., fold). The gap may be defined between each grommet and its immediately adjacent corner protrusion, at opposing ends of the associated wall and / or associated flap, e.g., along the lateral axis of the associated wall and / or flap. The gap may provide clearance between the folded corner protrusion and the grommet structure. The gap may hinder (e.g., prevent) interference between the corner protrusion and the grommet during assembly. The gap may be at least about 0.25 millimeters (mm), 0.5 mm, or 0.75 mm. The gap may be at most about 0.75 mm, 0.875 mm, 1 mm, or 1 .2 mm. The gap may be any value within the aforementioned values, e.g., from about 0.25 mm to about 1 .2 mm. The gap may be about 0.5 mm to about 1.2 mm. The gap may be maintained after the folding and / or any trimming operation, e.g., to promote (e.g., ensure) proper fit and / or alignment of the device components.

[0219] In some embodiments, a grommet distance may be defined along the lateral axis of its associated wall and / or flap. The grommet distance may be measured from a lateral edge of the flap in which the grommet is disposed in and / or of the wall of the central body. The grommet distance may be at least about 65 millimeters (mm), 67.5 mm, or 70 mm. The grommet distance may be at most about 70 mm, 70.12 mm, or 75 mm. The grommet distance may be any value within the aforementioned values, e.g., from about 65 mm to about 75 mm. The grommet distance may be about 70.24 mm. This distance may be measured along the extended length of the pouch from the folded corner protrusion to the grommet at the tab end. The grommet distance may facilitate dimensional coordination between the corner protrusion fold locationAttorney Docket No. ENX-0159.WO(e.g., at the end wall) and the grommet positioning (e.g., at the tab end wall) to minimize overall device volume.

[0220] In some embodiments, the energy manipulation device comprises a protection circuit module. The protection circuit module may be operatively coupled with the energy manipulation device, e.g., attached its enclosure and / or terminal tabs. The protection circuit module may be attached to a flap, e.g., weather in an open terrace, or a folded flap configuration. The protection circuit module may be attached to the terminal tabs. The attachment may be reversible or irreversible, e.g., by welding. The attachment may be performed after folding of the flap to which it is destined to attach, the folding of the flap being to the wall of the central body. The attachment may be performed after folding of one or more (e.g., all the) flaps of the enclosure. The attachment may be performed after the folding of the terminal tabs. The protection circuit module may comprise a printed circuit board (PCB). The PCB may comprise a flexible PCB. The flexible PCB may comprise a substrate. The BCP substrate may comprise a flexible substrate. The PCB substrate may comprise polyimide, polyester, polyethylene naphthalate, any plurality of types thereof, or any combination thereof. The PCB substrate may have a thickness of at least about 25 micrometers (pm), 50 pm, or 75 pm. The PCB substrate may have a thickness of at most about 75 pm, 100 pm, or 150 pm. The PCB thickness may be any value within the aforementioned values, e.g., from about 25 pm to about 150 pm.

[0221] In some embodiments, the protection circuit module comprises conductive traces. The conductive traces may be, or may correspond to, wiring. The conductive traces may be disposed on the PCB substrate. The conductive traces may comprise copper, aluminum, silver, gold, or any combination thereof. The conductive traces may electrically connect electronic components on the protection circuit module. The electronic components may comprise integrated circuits, resistors, capacitors, transistors, diodes, any plurality of types thereof, or any combination thereof. The conductive traces may be configured to carry electrical current between the terminal tabs and external terminals of the energy manipulation device.

[0222] In some embodiments, the protection circuit module comprises coupling pads such as welding pads and / or adhesion tabs. The adhesion tabs may accept a conductive adhesive such as disclosed herein, e.g., comprising conductive wiring and / or particulate matter such as powder. The coupling pads may be conductive areas configured to receive the terminal tabs. The coupling pads may be positioned as part of the protection circuit module, e.g., to align with positions of the terminal tabs. The coupling pads may comprise nickel, copper, nickel-plated copper, or any combination thereof. The coupling pads may be configured to withstand coupling temperatures. The coupling temperature may comprise adhesion and / or welding temperatures. The coupling temperatures may be at least about 200 degrees Celsius (°C), 300 °C, or 400 °C. The coupling temperatures may be at most about 400 °C, 500 °C, or 600 °C. The coupling temperature may be any value within the aforementioned values, e.g., from aboutAttorney Docket No. ENX-0159.WO200 °C to about 600 °C. The coupling pads may provide electrical connection between the terminal tabs and the protection circuit module. The coupling temperature and / or coupling tab location with respect to the device, may be selected to hinder (e.g., prevent) an adverse effect. The adverse effect can be to the energy manipulation device, to its user, to a facility in which the device is disposed, or any combination thereof. The coupling may be controlled, e.g., using a control system such as disclosed herein.

[0223] In some embodiments, a method comprises coupling (e.g., welding and / or adhering) the terminal tabs to the protection circuit module coupling pads. The welding may comprise resistance welding. Resistance welding may apply electrical current through the terminal tab and the welding pad. The electrical current may generate heat at an interface between the terminal tab and the welding pad. The heat may cause melting, liquification, fusion, or any combination thereof, of the terminal tab and / or of the welding pad. The welding may comprise ultrasonic welding. Ultrasonic welding may apply high-frequency vibrations to the cell tab and the welding pad. The vibrations may generate heat through friction. The welding may comprise laser welding. Laser welding may apply focused laser energy to the interface between the terminal tab and the welding tab. The laser beam may apply continuous or discontinuous (e.g., pulsed) energy to the interface.

[0224] In some embodiments, the protection circuit module is configured to monitor electrical parameters of the energy manipulation device. The electrical parameters may comprise voltage, current, temperature, impedance, or any combination thereof. The monitoring may be performed continuously, or intermittently, during operation of the energy manipulation device (e.g., battery). The monitoring may be performed at predetermined intervals. The predetermined intervals may be at least about every 1 millisecond (ms), every 10 ms, or every 100 ms. The predetermined intervals may be at most about every 100 ms, every 500 ms, or every 1 second. The intervals may be any value within the aforementioned values, e.g., from about every 1 ms to about every 1 second. The monitoring may use voltage sensors, current sensors, temperature sensors, pressure sensors, positional sensors, electromagnetic sensors, any other sensor disclosed herein, or any combination thereof. The sensors may be integrated into the protection circuit module, or may be otherwise operatively coupled thereto. The sensors may provide signals to a control system on the protection circuit module such as the control system disclosed herein.

[0225] In some embodiments, the protection circuit module is configured to hinder (e.g., prevent) over-charge conditions. The over-charge condition may occur when a voltage of the device exceeds a predetermined over-charge threshold. The predetermined over-charge threshold may be at least about 4.2 volts (V), 4.3 V, or 4.35 V per cell assembly. The predetermined over-charge threshold may be at most about 4.35 V, 4.375 V, 4.4 V, 4.6 V, or 4.8 V per cell assembly. The threshold may be any value within the aforementioned values,Attorney Docket No. ENX-0159.WO e.g., from about 4.2 V to about 4.8 V per cell assembly. The protection circuit module may disconnect a charging circuit when the over-charge condition is detected. The disconnection may be performed at least in part using a field-effect transistor, a relay, a mechanical switch, any plurality of types thereof, or any combination thereof. The disconnection may hinder (e.g., prevent) further charging of the energy manipulation device. The hindrance may increase protection for the cell assembly from the harmful effect(s), e.g., including from the damage due to over-charging. The damage from the harmful effect(s) being to the cell assembly, to the device, to the protection circuit module, or any combination thereof.

[0226] In some embodiments, the protection circuit module is configured to hinder (e.g., prevent) over-discharge conditions. The over-discharge condition may occur when a voltage of the device falls below a predetermined over-discharge threshold. The predetermined overdischarge threshold may be at least about 2.0 volts (V), 2.4 V, or 2.8 V per cell assembly. The predetermined over-discharge threshold may be at most about 2.8 V, 2.9 V, or 3.0 per cell assembly. The predetermined over-discharge threshold may be any value within the aforementioned values, e.g., from about 2.0 V to about 3.0 V per cell assembly. The protection circuit module may disconnect a load when the over-discharge condition is detected. The disconnection may hinder (e.g., prevent) further discharging of the device. The hindrance may protect the cell assembly from damage due to the adverse effects, e.g., due to overdischarging. The damage may comprise irreversible capacity loss, copper dissolution, cycle life, or any combination thereof. The damage being to the cell assembly, to the device, to the protection circuit module, or any combination thereof.

[0227] In some embodiments, the protection circuit module is configured to prevent overcurrent conditions. The over-current condition may occur when a current exceeds a predetermined current limit. The predetermined current limit may be at least about 3 amperes (A), 5 A, or 10 A. The predetermined current limit may be at most about 10 A, 12.5 A, or 15 A. The current limit may be any value within the aforementioned values, e.g., from about 3 A to about 15 A. The predetermined current limit may be based on a rated capacity of the energy manipulation device. The protection circuit module may interrupt the current flow when the over-current condition is detected. The interruption may be performed at least in part using a field-effect transistor with low on-resistance. The low on-resistance may be at most about 50 milliohms (mQ), 30 mfl, 20 mfi, or 10 mQ. The interruption may hinder (e.g., prevent) damage by the adverse effects, the damage being to the cell assembly, to the device, to the protection circuit module, or any combination thereof. The interruption may increase the protection of the cell assembly, of the device, of the protection circuit module, or any combination thereof.

[0228] In some embodiments, the protection circuit module is configured to hinder (e.g., prevent) short circuit conditions. The short circuit condition may occur when a resistance between positive and negative terminals falls below a predetermined resistance threshold. TheAttorney Docket No. ENX-0159.WO predetermined resistance threshold may be at least about 1 milliohm (mQ), 10 mfi, or 50 mQ. The predetermined resistance threshold may be at most about 50 mfl, 75 mQ, or 100 mQ. The resistance threshold may be any value within the aforementioned values, e.g., from about 1 mQ to about 100 mQ. The protection circuit module may detect the short circuit condition within a response time. The response time may be at least about 10 microseconds (ps), 100 ps, or 500 ps. The response time may be at most about 500 ps, 750 ps, or 1 millisecond (ms). The response time may be any value within the aforementioned values, e.g., from about 10 ps to about 1 ms. The protection circuit module may interrupt current flow immediately upon detecting the short circuit condition. The immediate interruption may hinder (e.g., prevent) damage to the device, to the end user device, to the facility in which the device is disposed, any other adverse effects such as disclosed herein, or any combination thereof. The immediate interruption may hinder (e.g., prevent) damage by the adverse effects, the damage being to the cell assembly, to the device, to the protection circuit module, or any combination thereof. The immediate interruption may increase the protection of the cell assembly, of the device, of the protection circuit module, or any combination thereof.

[0229] In some embodiments, the folding of the terminal tab(s) increases energy density of the device (e.g., battery). The energy density may be volumetric energy density. The volumetric energy density may be expressed in watt-hours per liter. The increase in volumetric energy density may be at least about 0.5 percent (%), 1 %, 2%, 2.5%, 3%, 4%, or 5% v / v, relative to an enclosure having an open terrace comprising the terminal tabs. The increase in volumetric energy density may be at most about 4%, 4.5%, 5%, or 10% v / v, relative to an enclosure having an open terrace comprising the terminal tabs. The increase in volumetric energy density may be any value within the aforementioned values, e.g. , from about 0.5% to about 10% v / v, relative to an enclosure having an open terrace comprising the terminal tabs. The increase of the energy density may depend at least in part on the height of the central body relative to the volume of the central body. The increase of the energy density may depend at least in part on the volume occupied by a terrace (open flap) in the target device relative to the volume of the rest of the enclosure, which volume occupied by a terrace is eliminated by folding that terrace flap onto a wall of the central body. The increase of the energy density may depend at least in part on the volume of the device relative to a volume occupied by an open flap (e.g., a terrace), having imaginary side walls that are extensions of respective sides of the enclosure, an imaginary cover extending from a cover of the enclosure, and an imaginary wall extending from an end of the flap towards an end of the imaginary cover extension, the imaginary wall being normal to the open terrace flap. In an example, the increase in energy density may be at least about 2.5%, or 2.7% v / v, relative to an enclosure having an open terrace comprising the terminal tabs. The increase may be measured relative to a comparable energy manipulationAttorney Docket No. ENX-0159.WO device with an unfolded tab end (e.g., terrace). The increase may result from more efficient use of available volume within an end user device housing.

[0230] In some embodiments, the increase in energy density of the device results at least in part from substitution of an inactive volume with an active volume. The inactive volume may comprise volume occupied by the unfolded flap constituting terrace. The terrace can occupy the terminal tabs. The active volume may comprise volume occupied by the cell assembly. The inactive volume may not contribute to energy storage capacity, e.g., since it is not occupied by the cell assembly. The active volume may contain anodically active material, cathodically active material, separator material, electrolyte, or any combination thereof. The substitution may allow for incorporation of additional cell assembly component (e.g., enlarged electrode, enlarged counter-electrode, and / or addition of unit cells) in the volume that has now been freed in the cavity of the target device. The additional cell assembly components may be positioned in a region previously occupied by the unfolded terrace and the open volume above it. The additional cell assembly components may increase total energy capacity of the energy manipulation device.

[0231] In some embodiments, the folding of the flaps reduces the overall device volume occupied in the cavity of the target device that is devoid of active material. The device volume devoid of active material may comprise a volume above a footprint of the enclosure having the height of the enclosure. The reduction in device volume devoid of active material may be at least about 0.5 percent (%), 1 %, 2%, 2.5%, 3%, 4%, or 5% v / v, relative to an enclosure having an open terrace comprising the terminal tabs. The reduction in device volume devoid of active material may be at most about 4%, 4.5%, 5%, or 10% v / v, relative to an enclosure having an open terrace comprising the terminal tabs. The reduction in device volume devoid of active material may be any value within the aforementioned values, e.g., from about 0.5% to about 10% v / v, relative to an enclosure having an open terrace comprising the terminal tabs. In an example, the reduction may be at least about 2.5%, or 2.6% v / v. The reduction in the device volume may be measured relative to a comparable energy manipulation device with an unfolded terrace. The reduction may improve the ratio of active material volume to total device volume.

[0232] In some embodiments, the reduction in device (e.g., battery) volume devoid of active material comprises dimensional reductions along multiple axes. The axes may comprise an X- axis, a Y-axis, and a Z-axis. The X-axis, Y-axis, and Z-axis may be mutually perpendicular. The reduction along the X-axis may be at least about 0.5 percent (%), 1.25%, or 2% v / v. The reduction along the X-axis may be at most about 2%, 2.05%, or 2.5% v / v. The reduction along the X-axis may be any value within the aforementioned values, e.g., from about 0.5% to about 2.5% v / v. In an example, the reduction the X-axis is at least about 2.0% v / v. The reduction along the Y-axis may be at least about 0.01 percent (%), 0.02%, or 0.03%. v / v. The reductionAttorney Docket No. ENX-0159.WO along the Y-axis may be at most about 0.03%, 0.04%, or 0.05% v / v. The reduction along the...

Claims

Attorney Docket No. ENX-0159.WOCLAIMSWhat is claimed is:1 . A device for energy manipulation, the device comprising: a cell assembly comprising an electrode separated from a counter-electrode by a gap, the electrode coupled with an electrode terminal tab, the counter-electrode coupled with a counter-electrode terminal tab; and an enclosure comprising (a) a central body having a height along a heigh direction, the central body being configured to house the cell assembly, and (b) an extension extending from a periphery of the central body, the extension comprising flaps folded respectively along fold lines having a vectorial component along the height direction, the flaps being folded towards respective sides of the central body, the flaps being attached with the central body, the flaps comprising a first flap, a third flap, and a fourth flap opposing the third flap, the first flap being coupled (a) with the third flap by a first fold and (b) with the fourth flap by a second fold, the first fold and the second fold being attached with the first flap such that the first fold and the second fold face each other, the extension comprising a seal configured to hermetically seal the cell assembly in the enclosure, the electrode terminal tab and the counter-electrode terminal tab extending from the cell assembly through the extension to an external environment to the enclosure, the first flap comprising one or more of (i) the electrode terminal tab and (ii) the counter-electrode terminal tab.

2. The device of claim 1 , wherein the enclosure comprises one or more layers having a thickness, and the folds are configured to increase the thickness by at most about four times the thickness, or three times the thickness.

3. The device of claim 1 , wherein the extension comprises a second flap, the electrode terminal tab being disposed in the first flap or in the second flap, and wherein the counterelectrode terminal tab is disposed in the first flap or in the second flap.

4. The device of claim 1 , wherein the cell assembly is coupled with a constraint system configured to curb volumetric change of the cell assembly during a prescribed operation of the device, the constraint system being disposed in the central body of the enclosure.

5. The device of claim 1 , wherein one or more of the folds are truncated.

6. The device of claim 1 , wherein (a) the electrode terminal tab and the counter-electrode terminal tab are folded with one or more of the flaps in which they are disposed, (b) the central body comprises a front side opposing a back side disposed at least partially in a plane, the electrode terminal tab and the counter-electrode terminal tab being folded from the back side to the front side, the electrode terminal tab and the counter-electrode terminal tab emerging from the enclosure from the front side, or (c) a combination of (a) and (b).

7. The device of claim 1 , wherein the device is configured to hinder rupture of the enclosure during a prescribed operation of the device and / or standard testing according toAttorney Docket No. ENX-0159.WO applicable jurisdictional and / or industrial standardized testing, of the device; wherein the device is configured to seal chemicals in the enclosure during the prescribed operation of the device and / or the standard testing.

8. The device of claim 1 , wherein the fold lines are disposed in a plane; and wherein the fold lines are disposed along a circumference of a back side of the central body opposing a front side of the central body, the back side and the front side being disposed along the height direction.

9. The device of claim 8, wherein the central body comprises a second side opposing the first side; and wherein the enclosure is configured to be enclosed in a cavity of a target device such that a controller of the energy manipulation device is coupled with the device externally to contact the enclosure such that it is parallel to one or more of the sides of the central body with which the flaps adhere.

10. The device of claim 8, wherein the central body comprises a second side opposing the first side.11 . The device of claim 1 , wherein the cell assembly comprises the electrode separated from the counter-electrode by a separator disposed in the gap, the separator being configured to allow charge carriers to travel therethrough.

12. The device of claim 1 , wherein the cell assembly comprises a wound cell.

13. The device of claim 1 , wherein the first flap is folded towards and is attached to a first side of the sides of the central body, the first flap being attached with the first side, the third flap is folded towards and is attached to a third side of the sides of the central body, and the fourth flap is folded towards and is attached to a fourth side of the sides of the central body.

14. The device of claim 13, wherein the extension comprises a second flap, the second flap being coupled (a) with the third flap by a third fold and (b) with the fourth flap by a fourth fold, the third fold and the fourth fold being attached with the second flap such that the third fold and the fourth fold face each other.

15. The device of claim 13, wherein the extension comprises a second flap opposing the first flap, the second flap being of the flaps folded respectively along the fold lines having the vectorial component along the height direction, the flaps being folded towards respective sides of the central body.

16. The device of claim 13, wherein the cell assembly comprises a stack of unit cells stacked along a stacking axis.

17. The device of claim 13, wherein the enclosure comprises a first portion adhered to a second portion.

18. The device of claim 13, wherein the central body comprises a second side opposing the first side; and wherein the extension comprises a second flap; and wherein (a) when unfolded, the first fold and the second fold, extend the first flap along a lateral direction, theAttorney Docket No. ENX-0159.WO first side having a vertical height normal to the lateral direction, the first flap extending at most to a vertical height, and (b) when unfolded, a third fold and a fourth fold, extend the second flap along the lateral direction, the second side having the vertical height normal to the lateral direction, the second flap extending at most to the vertical height.

19. The device of claim 13, wherein the extension comprises a second flap opposing the first flap, and the central body comprises a second side opposing the first side of the sides; and wherein (a) the third flap is folded onto and adhered with the third side using a first adhesive type, (b) the fourth flap is folded onto and adhered with the fourth side with the first adhesive type, (c) the first flap is folded onto and adhered with the first side with the first adhesive type, and (d) the second flap is folded onto and adhered with the second side with the first adhesive type; and wherein (i) the first fold and the second fold are folded onto and adhered with the first flap using a second adhesive type, and (ii) a third fold and a fourth fold are folded onto and adhered with the second flap using the second adhesive type.

20. The device of claim 1 , wherein the cell assembly is an electrochemical cell assembly, and wherein the device is a secondary battery.

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

22. A method of generating the device of any of claims 1 to 20, the method comprising using one or more operations to generate the device.

23. An apparatus for the energy manipulation, the apparatus comprising one or more controllers configured to (a) operatively couple with the device of any of claims 1 to 20, and (b) direct one or more components to store, transport, serve, upgrade, and / or use the device for the energy manipulation.

24. An apparatus for the energy manipulation, the apparatus comprising one or more controllers configured to direct one or more components to generate the device of any of claims 1 to 20.

25. Non-transitory computer-readable program instructions physically inscribed on at least one media, the program instructions, when read by one or more processors operatively coupled with the device of any of claims 1 to 20, cause the one or more processors to execute one or more operations for storing, transporting, servicing, upgrading, and / or using the device for the energy manipulation.

26. Non-transitory computer-readable program instructions physically inscribed on at least one media, the program instructions, when read by one or more processors operatively coupled with the device of any of claims 1 to 20, cause the one or more processors to execute one or more operations for generating the device for use in the energy manipulation.

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