Coated electrochemical separator assemblies and methods of producing the same

Abstract

Embodiments described herein relate to electrochemical cells with dendrite prevention mechanisms and improved ionic conduction, and methods of producing and operating the same. In some aspects, an electrochemical cell can include a first electrode disposed on a first current collector, a second electrode disposed on a second current collector, a first separator disposed on the first electrode, a second separator disposed on the second electrode; and an interlayer disposed between the first electrode and the second electrode. In some aspects, the first separator, the second separator, and the interlayer can be collectively referred to as a "separator assembly". In some aspects, at least one of the first separator or the second separator can include a first portion having a first property, and a second portion having a second property. In some aspects the second property can be different than the first property.

Description

Agent’s File Ref. 24MT-207 / 01WO 314552-3086COATED ELECTROCHEMICAL SEPARATOR ASSEMBLIES AND METHODS OF PRODUCING THE SAMECROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to and the benefit of U.S. Provisional Patent Application No. 63 / 738,371, filed December 23, 2024, and titled, “COATED ELECTROCHEMICAL SEPARATOR ASSEMBLIES AND METHODS OF PRODUCING THE SAME,” the disclosure of which is hereby incorporated by reference herein in its entirety.TECHNICAL FIELD

[0002] Embodiments described herein relate to electrochemical cells with multiple active layers and separator assemblies formulated to minimize damage from dendrite formation and improve active ion conductivity.BACKGROUND

[0003] Dendrite formation in electrochemical cells can lead to short circuiting and heat generation. Heat generation in electrochemical cells is a safety issue that can have dangerous results. Thermal runaway can lead to fires and thermal decomposition of the electrochemical cell materials. This issue is compounded in electrochemical cell stacks having a plurality of electrochemical cells as more heat is generated, and, hence, the risk of thermal runaway is even higher. Moreover, electrochemical cell stacks typically include a high inactive to active material ratio, which is an inefficient use of space and can adversely affect overall performance of the cell. Furthermore, electrochemical cells or cell stacks including conventional separators typically have poor ion conductivity through the separator, which can lead to poor capacity retention and charge / discharge rate performance.SUMMARY

[0004] Embodiments described herein relate to electrochemical cells with dendrite prevention mechanisms and improved ionic conduction, and methods of producing and operating the same. In some aspects, an electrochemical cell can include a first electrode disposed on a first current collector, a second electrode disposed on a second current collector, a first separator disposed on the first electrode, a second separator disposed on the second1328896850Agent’s File Ref. 24MT-207 / 01WO 314552-3086electrode; and an interlayer disposed between the first electrode and the second electrode. In some aspects, the first separator, the second separator, and the interlayer can be collectively referred to as a “separator assembly”.

[0005] In some aspects, at least one of the first separator or the second separator can include a first portion having a first property, and a second portion having a second property. In some aspects the second property can be different than the first property. In some aspects, the first portion can be configured to remain substantially planar. In some aspects, the second portion can be configured to bend about an axis. In some aspects, the first property can be a first flexural modulus, and the second property can be a second flexural modulus. In some aspects, the second flexural modulus can be less than the first flexural modulus. In some aspects, the first property can be a first flexural rigidity, and the second property can be a second flexural rigidity. In some aspects, the second flexural rigidity can be less than the first flexural rigidity. In some aspects, the first property can be a first elastic modulus, and the second property can be a second elastic modulus. In some aspects, the second elastic modulus can be less than the first elastic modulus.

[0006] In some aspects, an electrochemical cell can include an anode disposed on an anode current collector, a cathode disposed on a cathode current collector, and a separator assembly disposed between the anode and the cathode. In some aspects, the separator assembly can include a first portion and a second portion. In some aspects, the first portion can have a first flexural modulus, and the second portion can have a second flexural modulus. In some aspects, the second flexural modulus can be different than the first flexural modulus. In some aspects, the first flexural modulus can be greater than the second flexural modulus.

[0007] It should be appreciated that all combinations of the foregoing concepts and additional concepts discussed in greater detail below (provided such concepts are not mutually inconsistent) are contemplated as being part of the inventive subject matter disclosed herein. In particular, all combinations of claimed subject matter appearing at the end of this disclosure are contemplated as being part of the inventive subject matter disclosed herein.BRIEF DESCRIPTION OF THE DRAWINGS

[0008] FIG. 1 is a block diagram of an electrochemical cell including a plurality of separators and an interlayer, according to an embodiment.2328896850Agent’s File Ref. 24MT-207 / 01WO 314552-3086|0009] FIG. 2 is a schematic illustration of an electrochemical cell including a plurality of separators and an interlayer in a planar configuration, according to an embodiment.[001.0] FIG. 3 is a schematic illustration of a separator assembly including a plurality of separators and an interlayer in a folded configuration, according to an embodiment.[00111 FIG. 4 is a schematic illustration of an electrochemical cell assembly with multiple electrodes and a separator assembly including a plurality of separators and an interlayer, according to an embodiment.

[0012] FIG. 5 is a block diagram of a method of forming an electrochemical cell including a plurality of separators and an interlayer, according to an embodiment.DETAILED DESCRIPTION|0013] Embodiments described herein relate to cells with interlayers, and methods of operating the same. An interlayer can include a layer of electroactive material placed between an anode and a cathode of an electrochemical cell. The interlayer can be disposed between a first separator and a second separator. Interlayers can be used to detect dendrites before they grow too large, such that the dendrites would cause safety hazards. A battery management system (BMS) can be connected to the electrochemical cell to detect when a dendrite enters the interlayer and safely discharge the remaining energy in the electrochemical cell.

[0014] In some embodiments, the discharge energy can be used to power other devices, such as heaters, removing cell energy to create a safe condition. The first separator or the second separator can have multiple portions with different properties (e.g., different mechanical properties or material properties). The first separator can include a first portion having a first property (e.g., flexural rigidity, ionic conductivity, porosity, etc.) and a second portion having a second property (e.g., flexural rigidity, ionic conductivity, porosity, etc.), the second property different than the first property. Likewise, the second separator can have a first portion having a first property (e.g., flexural rigidity, ionic conductivity, porosity, etc.) and a second portion having a second property (e.g., flexural rigidity, ionic conductivity, porosity, etc.), the second property different than the first property. In this way, multifunctional separators may be created which include segments or portions, for example, having high ionic transport, and other segments or portions having high flexibility or bendability.10015] Further descriptions of electrochemical cells with multiple separators and interlayers can be found in U.S. Patent Publication No. 2022 / 0352597 (“the ‘597 publication”),3328896850Agent’s File Ref. 24MT-207 / 01WO 314552-3086filed April 29, 2022 and titled “Electrochemical Cells with Multiple Separators and Methods of Producing the Same,” the disclosure of which is hereby incorporated by reference in its entirety.

[0016] Further descriptions of electrochemical cells with interlayers can be found in U.S.Patent No. 12,100,816 (“the ‘816 patent”), filed December 18, 2022 and titled “Systems and Methods for Minimizing and Preventing Dendrite Formation in Electrochemical Cells,” the disclosure of which is hereby incorporated by reference in its entirety. In some embodiments, the interlayers described herein can be the same, or substantially the same, as the interlayers described in the ‘816 patent.

[0017] In some embodiments, electrodes described herein can include conventional solid electrodes. In some embodiments, the solid electrodes can include binders. In some embodiments, electrodes described herein can include semi-solid electrodes. Semi-solid electrodes described herein can be made: (i) thicker (e.g., greater than 100 pm - up to 2,000 pm or even greater) due to the reduced tortuosity and higher electronic conductivity of the semi-solid electrode, (ii) with higher loadings of active materials, and (iii) with a simplified manufacturing process utilizing less equipment. These relatively thick semi-solid electrodes decrease the volume, mass and cost contributions of inactive components with respect to active components, thereby enhancing the commercial appeal of batteries made with the semi-solid electrodes. In some embodiments, the semi-solid electrodes described herein are binderless and / or do not use binders that are used in conventional battery manufacturing. Instead, the volume of the electrode normally occupied by binders in conventional electrodes, is now occupied by: 1) electrolyte, which has the effect of decreasing tortuosity and increasing the total salt available for ion diffusion, thereby countering the salt depletion effects typical of thick conventional electrodes when used at high rate, 2) active material, which has the effect of increasing the charge capacity of the battery, or 3) conductive additive, which has the effect of increasing the electronic conductivity of the electrode, thereby countering the high internal impedance of thick conventional electrodes. The reduced tortuosity and a higher electronic conductivity of the semi-solid electrodes described herein, results in superior rate capability and charge capacity of electrochemical cells formed from the semi-solid electrodes. Since the semi-solid electrodes described herein, can be made substantially thicker than conventional electrodes, the ratio of active materials (i.e., the semi-solid cathode and / or anode) to inactive materials (i.e., the current collector and separator) can be much higher in a battery formed from electrochemical cell stacks that include semi-solid electrodes relative to a similar battery4328896850Agent’s File Ref. 24MT-207 / 01WO 314552-3086formed form electrochemical cell stacks that include conventional electrodes. This substantially increases the overall charge capacity and energy density of a battery that includes the semi-solid electrodes described herein.

[0018] In some embodiments, the electrode materials described herein can be a flowable semi-solid or condensed liquid composition. In some embodiments, the electrode materials described herein can be binderless or substantially free of binder. A flowable semi-solid electrode can include a suspension of an electrochemically active material (anodic or cathodic particles or particulates), and optionally an electronically conductive material (e.g., carbon) in a non-aqueous liquid electrolyte. Said another way, the active electrode particles and conductive particles are co-suspended in an electrolyte to produce a semi-solid electrode.Conventional separators are often used to electrically isolate or insulate the cathode and the anode while allowing ionic transport therebetween. They can include ion-permeable membranes which are electrically inactive or electrically insulative materials. Conventional separator materials are generally very flexible, and thus, are suitable for many different electrochemical cell geometries. These can include stacked configurations or wound configurations which may require bending of the separator. By using a stacked configuration or a wound configuration of several anode-cathode pairs with a corresponding separator therebetween, one can increase the amount of active material or the ratio of active materials to inactive materials, and hence, increase the capacity of the cell. Likewise, by intentionally selecting the numbers of electroactive layers (e.g., cathodes or anodes) in the stacked or wound electrochemical cell assembly, the electrochemical cell assembly can be adapted to have a desired capacity to suit many secondary battery needs, such as in consumer electronics. This is especially true for semi-solid cathode or semi-solid anode materials, which have reduced tortuosity over conventional electrode materials, thereby enabling access to more of the capacity of each electrode and incorporation of significantly thicker electrodes in the electrochemical cell, as previously described.

[0020] While including semi-solid electrodes may decrease tortuosity through the electrode and enable a corresponding increase in capacity of the cell, ionic transport rates between electrodes remain limited by poor ionic conductivities of conventional separator materials. This is compounded in electrochemical cell assemblies and / or separator assemblies having multiple separators, as each subsequent separator layer would contribute to further conductivity losses in the cell. Hence, electrochemical cells including one or more separators formed primarily of conventional separator materials are generally not suitable for high charge5328896850Agent’s File Ref. 24MT-207 / 01WO 314552-3086rate applications, such as in electric vehicles. Such applications can desire increasingly fast charging rates to meet consumer demand.

[0021] Alternatively, solid-state electrolytes between electrodes (e.g., included in separators or used as separators) may provide electrical isolation between electrodes while increasing ionic transport rates between electrodes. However, solid-state electrolytes are significantly more rigid or stiff, or less bendable than conventional separator materials, and thus, it is difficult to incorporate solid-state electrolytes in stacks of electrochemical cells without including several layers of solid-state electrolytes and / or increasing the amount of inactive space in the cell. Such inactive volumes are an inefficient use of space in the cell that may be detrimental to the capacity and overall performance of the cell. This is especially true for electrochemical cells in a wound configuration, or for configurations which require bending of the separator, such as when including a serpentine separator between electrodes in a stacked configuration with multiple electrochemical cells. Hence, solid-state electrolytes are difficult to incorporate into a variety of cell geometries without causing an undesirable decrease in the ratio of active material to inactive material and causing a corresponding decrease in capacity or performance in the cell.

[0022] In contrast, embodiments of the electrochemical cell described herein, which may include one or more separators with a first portion having a first property and a second portion having a second property, may provide advantages including, for example: 1) improved conductivity of ions between electrodes; 2) faster charge or discharge rates; 3) reduced charge times, for example, for batteries in electric vehicles (EVs) or EV applications; 4) improved capacity retention of the electrochemical cell after multiple charge / discharge cycles; 5) improved cyclability of the electrochemical cell; 6) separators with portions having high ionic transport properties and portions capable of bending; 7) multi-functional separators or multifunctional separator assemblies including multiple separators and / or interlayers; 8) more flexibility in design of the electrochemical cell or electrochemical cell assemblies; 9) more versatility in the build of the electrochemical cell or electrochemical cell assemblies; 10) reduced wasted or inactive space in electrochemical cells, 11) monitoring of voltages between electrodes and / or the interlayer(s); 12) monitoring of dendrite growth in the electrochemical cell; 13) inhibition or prevention of growth of dendrites in the electrochemical cell; 14) inhibition or prevention of dendrites from protruding through the separator; 15) inhibition or prevention of short circuit events or thermal runaway events of the electrochemical cell caused by dendrites; 15) separator assemblies with regions of high ionic transport and regions of high6328896850Agent’s File Ref. 24MT-207 / 01WO 314552-3086flexibility; and / or 16) improvement of overall performance (e.g., ionic transport) and safety of electrochemical cell or electrochemical cell assemblies.

[0023] As used in this specification, the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, the term “a member” is intended to mean a single member or a combination of members, “a material” is intended to mean one or more materials, or a combination thereof.

[0024] The term “substantially” when used in connection with “cylindrical,” “linear,” and / or other geometric relationships is intended to convey that the structure so defined is nominally cylindrical, linear or the like. As one example, a portion of a support member that is described as being “substantially linear” is intended to convey that, although linearity of the portion is desirable, some non-linearity can occur in a “substantially linear” portion. Such nonlinearity can result from manufacturing tolerances, or other practical considerations (such as, for example, the pressure or force applied to the support member). Thus, a geometric construction modified by the term “substantially” includes such geometric properties within a tolerance of plus or minus 5% of the stated geometric construction. For example, a “substantially linear” portion is a portion that defines an axis or center line that is within plus or minus 5% of being linear.

[0025] As used herein, the term “set” and “plurality” can refer to multiple features or a singular feature with multiple parts. For example, when referring to a set of electrodes, the set of electrodes can be considered as one electrode with multiple portions, or the set of electrodes can be considered as multiple, distinct electrodes. Additionally, for example, when referring to a plurality of electrochemical cells, the plurality of electrochemical cells can be considered as multiple, distinct electrochemical cells or as one electrochemical cell with multiple portions. Thus, a set of portions or a plurality of portions may include multiple portions that are either continuous or discontinuous from each other. A plurality of particles or a plurality of materials can also be fabricated from multiple items that are produced separately and are later joined together (e.g., via mixing, an adhesive, or any suitable method).

[0026] As used herein, the term “semi-solid” refers to a material that is a mixture of liquid and solid phases, for example, such as a particle suspension, a slurry, a colloidal suspension, an emulsion, a gel, or a micelle.

[0027] FIG. 1 is a block diagram of an electrochemical cell 100 with an interlayer 160, according to an embodiment. As shown, the electrochemical cell 100 includes an anode 1107328896850Agent’s File Ref. 24MT-207 / 01WO 314552-3086disposed on an anode current collector 120 and a cathode 130 disposed on a cathode current collector 140. The electrochemical cell 100 further includes a first separator 150a and a second separator 150b (collectively referred to herein as “separators 150”) disposed between the anode 110 and the cathode 130. The interlayer 160 can be disposed between the first separator 150a and the second separator 150b. The electrochemical cell 100 can include a first portion 152a and / or a second portion 154a in the first separator 150a. Likewise, the electrochemical cell 100 can include a first portion 152b and / or a second portion 154b in the second separator 150b.

[0028] In some embodiments, the first separator 150a, second separator 150b, and interlayer 160 can be collectively referred to as “separator assembly”. In some embodiments, the first separator 150a can be disposed on the anode 110 and the second separator 150b can be disposed on the cathode 130, or vice versa.

[0029] As shown, the first separator 150a is disposed on the anode 110 while the second separator 150b is disposed on the cathode 130. In some embodiments, the separators 150 can be disposed on their respective electrodes during production of the electrochemical cell 100. In some embodiments, the first separator 150a and / or the second separator 150b can include, be composed of, or be formed from polyethylene, polypropylene, high density polyethylene, polyethylene terephthalate, polystyrene, a thermosetting polymer, hard carbon, a thermosetting resin, a polyimide, a ceramic coated separator, an inorganic separator, cellulose, glass fiber, a polyethyleneoxide (PEO) polymer in which a lithium salt is complexed to provide lithium conductivity, NATION™ membranes which are proton conductors, or any other suitable separator material, or combinations thereof. In some embodiments, the first separator 150a can include the same material as the second separator 150b. In some embodiments, the first separator 150a can include a different material from the second separator 150b.

[0030] In some embodiments, the first separator 150a and / or the second separator 150b can have a porosity of at least about 10%, at least about 15%, at least about 20%, at least about 25%, at least about 30%, at least about 35%, at least about 40%, at least about 45%, at least about 50%, at least about 55%, at least about 60%, at least about 65%, at least about 70%, at least about 75%, at least about 80%, at least about 85%, or at least about 90%. In some embodiments, the first separator 150a and / or the second separator 150b can have a porosity of no more than about 95%, no more than about 90%, no more than about 85%, no more than about 80%, no more than about 75%, no more than about 70%, no more than about 65%, no more than about 60%, no more than about 55%, no more than about 50%, no more than about8328896850Agent’s File Ref. 24MT-207 / 01WO 314552-308645%, no more than about 40%, no more than about 35%, no more than about 30%, no more than about 25%, no more than about 20%, or no more than about 15%.

[0031] Combinations of the above-referenced porosity percentages of the first separator 150a and / or the second separator 150b are also possible (e.g., at least about 10% and no more than about 95% or at least about 20% and no more than about 40%), inclusive of all values and ranges therebetween. In some embodiments, the first separator 150a and / or the second separator 150b can have a porosity of about 10%, about 15%, about 20%, about 25%, about 30%, about 35%, about 40%, about 45%, about 50%, about 55%, about 60%, about 65%, about 70%, about 75%, about 80%, about 85%, about 90%, or about 95%.

[0032] In some embodiments, the first separator 150a can have a different porosity from the second separator 150b. In some embodiments, the porosities of the first separator 150a and the second separator 150b can be selected based on the difference between an anolyte (i.e., the electrolyte included in or in contact with the anode 110) and a catholyte (i.e., the electrolyte included in or in contact with the cathode 130). For example, if the catholyte has a higher vapor pressure and faster evaporation properties than the anolyte, then the second separator 150b can have a lower porosity than the first separator 150a. The lower porosity of the second separator 150b can at least partially prevent the catholyte from evaporating during production.

[0033] In some embodiments, the first separator 150a can include a different material from the second separator 150b. In some embodiments, the materials of the first separator 150a and the second separator 150b can be selected to facilitate wettability of the first separator 150a with the anolyte and the second separator 150b with the catholyte. For example, an ethylene carbonate / propylene carbonate-based catholyte can wet a polyethylene separator better than a polyimide separator, based on the molecular properties of the materials. An ethylene carb onate / di -methyl carbonate-based anolyte can wet a polyimide separator better than a polyethylene separator. A full wetting of the first separator 150a and the second separator 150b can facilitate better transport of electroactive species via the separators 150 (e.g., ions through the separator 150 while inhibiting transport of electrons therethrough). This transport can be facilitated particularly well when the first separator 150a physically contacts the second separator 150b.

[0034] As shown, the electrochemical cell 100 includes two separators 150a and 150b. In some embodiments, the electrochemical cell 100 can include 3, 4, 5, 6, 7, 8, 9, 10, or more than 10 separators 150. In some embodiments, a layer of liquid electrolyte (not shown) can be9328896850Agent’s File Ref. 24MT-207 / 01WO 314552-3086disposed between the first separator 150a and the second separator 150b, for example, to promote better adhesion between the separators 150.

[0035] In some embodiments, the first separator 150a and / or the second separator 150b can have a thickness of at least about 0.5 pm, at least about 1 pm, at least about 2 pm, at least about 3 pm, at least about 4 pm, at least about 5 pm, at least about 6 pm, at least about 7 pm, at least about 8 pm, at least about 9 pm, at least about 10 pm, at least about 15 pm, at least about 20 pm, or at least about 25 pm. In some embodiments, the first separator 150a and / or the second separator 150b can have a thickness of no more than about 30 pm, no more than about 25 pm, no more than about 20 pm, no more than about 15 pm, no more than about 10 pm, no more than about 9 pm, no more than about 8 pm, no more than about 7 pm, no more than about 6 pm, no more than about 5 pm, no more than about 4 pm, no more than about 3 pm, no more than about 2 pm, or no more than about 1 pm. Combinations of the above-referenced thicknesses of the first separator 150a and / or the second separator 150b are also possible (e.g., at least about 0.5 pm and no more than about 30 pm or at least about 5 pm and no more than about 20 pm), inclusive of all values and ranges therebetween. In some embodiments, the first separator 150a and / or the second separator 150b can have a thickness of about 0.5 pm, about 1 pm, about 2 pm, about 3 pm, about 4 pm, about 5 pm, about 6 pm, about 7 pm, about 8 pm, about 9 pm, about 10 pm, about 15 pm, about 20 pm, about 25 pm, or about 30 pm. In some embodiments, the first separator 150a can have a thickness the same or substantially similar to the thickness of the second separator 150b. In some embodiments, the first separator 150a can have a thickness greater or less than a thickness of the second separator 150b.

[0036] In some embodiments, the first separator 150a, the second separator 150b, and the interlayer 160 can form a film, for example, a laminated film. In some embodiments, the film can have a total thickness of at least about 5 pm, at least about 6 pm, at least about 7 pm, at least about 8 pm, at least about 9 pm, at least about 10 pm, at least about 15 pm, at least about 20 pm, at least about 25 pm, at least about 30 pm, at least about 35 pm, at least about 40 pm, or at least about 45 pm. In some embodiments, the film can have a total thickness of no more than about 50 pm, no more than about 45 pm, no more than about 40 pm, no more than about 35 pm, no more than about 30 pm, no more than about 25 pm, no more than about 20 pm, no more than about 15 pm, no more than about 10 pm, no more than about 9 pm, no more than about 8 pm, no more than about 7 pm, or no more than about 6 pm. Combinations of the above-referenced thicknesses are also possible (e.g., at least about 5 pm and no more than about 50 pm or at least about 10 pm and no more than about 40 pm), inclusive of all values and10328896850Agent’s File Ref. 24MT-207 / 01WO 314552-3086ranges therebetween. In some embodiments, the film can have a total thickness of about 5 gm, about 6 gm, about 7 gm, about 8 gm, about 9 gm, about 10 gm, about 15 gm, about 20 gm, about 25 gm, about 30 gm, about 35 gm, about 40 gm, about 45 gm, or about 50 gm.[00371 In some embodiments, the first separator 150a and / or the second separator 150b can include a solid-state electrolyte sheet. In some embodiments, the solid-state electrolyte sheet can replace the first separator 150a and / or the second separator 150b. In some embodiments, the first separator 150a and / or the second separator 150b can be made with a separator film. In some embodiments, the first separator 150a and / or the second separator 150b can include a coating polymer, a spray polymer, and / or a print polymer. In some embodiments, the first separator 150a and / or the second separator 150b can include a ceramic powder. In some embodiments, the first separator 150a and / or the second separator 150b can be absent of a ceramic powder. In some embodiments, the first separator 150a and / or the second separator 150b can include a ceramic with a liquid electrolyte and / or a solid-state electrolyte.

[0038] As shown, in some embodiments, one or more of the separators 150 may include a plurality of distinct segments or portions (e.g., first portion(s) 152a, 152b and second portion(s) 154a, 154b). In some embodiments, the first separator 150a may include the first portion 152a and the second portion 154a. In some embodiments, the second separator 150b may include the first portion 152b and the second portion 154b. In some embodiments, the first portion 152a of the first separator 150a may be distinct (e.g., independent, selected independently) from the first portion 152b of the second separator 150b. Likewise, in some embodiments, the second portion 154a of the first separator 150a may be distinct (e.g., independent, selected independently) from the second portion 154b of the second separator 150b. In some embodiments, the first portion 152a of the first separator 150a may be substantially similar to, or the same as, the first portion 152b of the second separator 150b. Hence, the first portion 152a of the first separator 150a and the first portion 152b of the second separator 150b may be collectively referred to as “first portion(s) 152”. Likewise, in some embodiments, the second portion 154a of the first separator 150a may be substantially similar to, or the same as, the second portion 154b of the second separator 150b. Hence, the second portion 154a of the first separator 150a and the second portion 154b of the second separator 150b may be collectively referred to as “second portion(s) 154”. In some embodiments, the first portions 152a and 152b may be contiguous or aligned with each other. Similarly, the second portions 154a and 154b may be contiguous or aligned with each other.11328896850Agent’s File Ref. 24MT-207 / 01WO 314552-3086

[0039] In some embodiments, the first portion(s) 152 may be substantially similar to, or the same as, the second portion(s) 154, for example, include the same materials and / or structure to each other. In some embodiments, the first portion(s) 152 may be distinct from (e.g., independent from, selected independently from) or different than the second portion(s) 154. For example, in some embodiments, the first portion(s) 152 and the second portion(s) 154 may include, or be composed of, different materials.

[0040] In some embodiments, the first portion(s) 152 and / or the second portion(s) 154 can include conventional separator materials. For example, in some embodiments, the first portion(s) 152 and / or the second portion(s) 154 can include any conventional membrane that is capable of ion transport, (i.e., an ion-permeable membrane). In some embodiments, the first portion(s) 152 and / or the second portion(s) 154 can include a liquid impermeable membrane that permits the transport of ions therethrough, namely a solid or gel ionic conductor. In some embodiments, the first portion(s) 152 and / or the second portion(s) 154 can include a porous polymer membrane, such as a porous polymer membrane infused with a liquid electrolyte, which allows for the shuttling of ions between electroactive materials of the cathode 130 and the anode 110, while preventing the transfer of electrons. In some embodiments, the first portion(s) 152 and / or the second portion(s) 154 can include a microporous membrane that inhibits particles included in compositions of the cathode 130 or the anode 110 from crossing the membrane (e.g., allow electrolyte transport while inhibiting active material and / or conductive material to cross therethrough).

[0041] In some embodiments, the first portion(s) 152 and / or the second portion(s) 154 includes a single or multilayer microporous separator, optionally with the ability to fuse or “shut down” above a certain temperature so that it no longer transmits working ions (e.g., the type used in the lithium ion battery industry and well-known to those skilled in the art). In some embodiments, the first portion(s) 152 and / or the second portion(s) 154 can include a polyethyleneoxide (PEO) polymer in which a lithium salt is complexed to provide lithium conductivity, or NAFION™ membranes which are proton conductors. For example, PEO-based electrolytes can be included in the first portion(s) 152 or the second portion(s) 154, which may be substantially pinhole-free and a solid ionic conductor, optionally stabilized with other membranes such as glass fiber separators as supporting layers. PEO can also be used as a slurry stabilizer, dispersant, etc., in positive or negative redox compositions. PEO is stable in contact with typical alkyl carbonate-based electrolytes. This can be especially useful in phosphate-based cell chemistries with cell potential at the positive electrode that is less than about 3.6 V12328896850Agent’s File Ref. 24MT-207 / 01WO 314552-3086with respect to Li metal. The operating temperature of the redox cell can be elevated as necessary to improve the ionic conductivity of the membrane.

[0042] In some embodiments, the first portion(s) 152 can include (e.g., incorporate) a solid-state electrolyte (SSE). In some embodiments, the solid-state electrolyte can include at least one of a sulfide solid-state electrolyte, an oxide-based solid electrolyte material including a garnet structure, a perovskite structure, a phosphate-based Lithium Super Ionic Conductor (LISICON) structure, a sodium ion conductor, beta / beta AI2O3, sodium super ionic conductor NASICON (Nai+xZr2SixP3-xOi2, where 0 < x < 3 ), sodium sulfide Na3PS4, Na3AsS4, Na3SbS4, Na4SiS4, Na4GeS4, Na4SnS4, NanSi2PSi2, NanSmSbSn, closo-type, Na(Cb910)CBuHi2), NaCBnHn, NaCBgHio, a glass structure such as Lao.5lLio.34TiO2.94, Lii.3Alo.3Tii.7(P04)3, Lii.4Alo.4Tii.6 P04)3, Li?La3Zr20i2, Li6.66La3Zn.6Tao.40i2.9 (LLZO), 50Li4SiO4.50Li3BC>3, Li2.9PO3.3N0.46 (lithium phosphorousoxynitride, LiPON), Li3.6Sio.6Po.4O4, Li3BN2, LisBOs — Li2SO4, LisBOs — Li2SO4 — Li2CO3 (LIB SCO, pseudoternary system), a thio-LISICON structure, a glassy structure, a glass-ceramic structure, Lii.o7Alo.69Tii.46(P04)3, Lii.5Alo.5Gei.5 P04)3, LiioGeP2Si2 (LGPS), 30Li2S.26B2S3.44LiI, 63Li2S.36SiS2.1Li3PO4, 57Li2S.38SiS2.5Li4SiO4, 70Li2S.30P2S5, 50Li2S.50GeS2, Li7P3Sn, Li3.25P0.95S4, and Li9.54Sii.74Pi.44Sn.7Clo.3, and / or lithium argyrodite LiePSsX (X= Cl, Br) and / or halide electrolytes s Li3-xMi-xXe (M = Y, Er, In, Yb, Ho, X= Cl, Br, I, Fand / or closo-type complex hydride solid electrolyte such as LiBHi — Lil, LiBHi — LiNH2. LiBH4 — P2S5, Li(CBxHx+i) — Lil like Li(CB9Hio) — Lil, and / or lithium electrolyte salt bis(trifluoromethane)sulfonamide (TFSI), bis(pentalluoroethanesulfonyl)imide (BETI), bis(fluorosulfonyl)imide, lithium borate oxalato phosphine oxide (LiBOP), lithium bis(fluorosulfonyl)imide, amide-borohydride, LiBF4, LiPFe, or LIF, or a salt such as, for example, a sodium, potassium, magnesium, zinc, cesium, indium, tin, antimony, silicon, nickel, or cobalt salt, or analogues of the aforementioned salts.

[0043] . In some embodiments, the first portion(s) 152 can include carbon fiber. In some embodiments, the first portion(s) 152 can include a carbon fiber sheet. In some embodiments, the separators 150 can include patterned solid-state electrolyte-coated sections and non-coated sections to allow for folding. In some embodiments, the first portions 152 can include a plastic / metal composite coating the separators 150.

[0044] In some embodiments, the first portion(s) 152 can be coated by the solid-state electrolyte. In some embodiments, the first portion(s) 152 can incorporate the solid-state electrolyte therein. For example, in some embodiments, the first portion(s) 152 can include a13328896850Agent’s File Ref. 24MT-207 / 01WO 314552-3086plurality of pores. In some embodiments, the solid-state electrolyte can be disposed in at least a portion of the plurality of pores. In some embodiments, the solid-state electrolyte can be embedded in the first portion(s) 152, such as embedded (e.g., incorporated) into one or more of the plurality of pores of the first portion(s) 152. In some embodiments, the first portion(s) 152 can be formed substantially of solid-state electrolyte. In some embodiments, the first portion(s) 152 do not include conventional separator materials and / or are formed substantially of solid-state electrolyte and / or other additives (e.g., binders).

[0045] In some embodiments, the second portion(s) 154 can include, or be formed substantially of conventional separator materials. For example, in some embodiments, the second portion(s) 154 can be any conventional membrane that is capable of ion transport, i.e., an ion-permeable membrane. In some embodiments, the second portion(s) 154 is a liquid impermeable membrane that permits the transport of ions therethrough, namely a solid or gel ionic conductor. In some embodiments the second portion(s) 154 is a porous polymer membrane infused with a liquid electrolyte that allows for the shuttling of ions between the semi-solid cathode 130 and the semi-solid anode 110 electroactive materials, while preventing the transfer of electrons. In some embodiments, the second portion(s) 154 is a microporous membrane that inhibits particles included in the cathode 130 or the anode 110 compositions from crossing the membrane. In some embodiments, the second portion(s) 154 is a single or multilayer microporous separator, optionally with the ability to fuse or “shut down” above a certain temperature so that it no longer transmits working ions, of the type used in the lithium ion battery industry and well-known to those skilled in the art. In some embodiments, the second portion(s) 154 can include a polyethyleneoxide (PEO) polymer in which a lithium salt is complexed to provide lithium conductivity, or NAFION™ membranes which are proton conductors. For example, PEO based electrolytes can be used as the second portion(s) 154 which is pinhole-free and a solid ionic conductor, optionally stabilized with other membranes such as glass fiber separators as supporting layers. PEO can also be used as a slurry stabilizer, dispersant, etc. in the positive or negative redox compositions. PEO is stable in contact with typical alkyl carbonate-based electrolytes. This can be especially useful in phosphate-based cell chemistries with cell potential at the positive electrode that is less than about 3.6 V with respect to Li metal.10046] The operating temperature of the redox cell can be elevated as necessary to improve the ionic conductivity of the membrane. In some embodiments, the second portion(s) 154 can be substantially free of solid-state electrolyte. In some embodiments, the second portion(s)14328896850Agent’s File Ref. 24MT-207 / 01WO 314552-3086154 do not include the solid-state electrolyte. In some embodiments, each of the first portion(s) 152 and the second portion(s) 154 may include corresponding axial ends. In some embodiments, axial end(s) of the first portion(s) 152 may be coupled to axial end(s) of the second portion(s) 154 to form the separator(s) 150. In some embodiments, the first portion(s) 152 and the second portion(s) 154 may be extruded or formed from the same (e.g., a single), or a continuous, piece of material to form the separator(s) 150. For example, in some embodiments in which the first portion(s) 152 and the second portion(s) 154 are extruded from a continuous piece of material, the first portion(s) 152 may be coated, or embedded, with the solid-state electrolyte, and the second portion(s) 154 may remain, or be, substantially free of solid-state electrolyte. For example, while incorporating the solid-state electrolyte into the separator(s) 150, regions may, for example, be masked (e.g., covered, blocked) to form the second portion(s) 154 that are substantially from the solid-state electrolyte, and regions may be unmasked (e.g., uncovered, unblocked) to form the first portion(s) 152 that include the solid-state electrolyte.(0047] Without being bound by theory, including the solid-state electrolyte material in the first portion(s) 152 of the separator(s) 150 can improve ionic conductivity between the anode 110 and the cathode 130 over conventional separator materials. However, doing so may increase the stiffness or rigidity of the first portion(s) 152 of the separator(s) 150 over other portion(s) of the separator(s) 150 that are free, or substantially free, of the solid-state electrolyte, such that the first portion(s) 152 of the separator(s) 150 may be difficult to bend and / or may remain substantially planar. Therefore, in some embodiments, it may be advantageous to include the second portion(s) 154 of the separator(s) 150, which are substantially free of the solid-state electrolyte. In some embodiments, the second portion(s) 154 does not, or do not, include the solid-state electrolyte. Without being bound by theory, including the second portion(s) 154 of the separator(s) 150 which is substantially free of solid-state electrolyte may facilitate bending of the second portion(s) 154, such that the second portion(s) 154 may be configured to bend about an axis. This may, for example, enable separator(s) 150 that are multi-functional and which may include segments or portions that are bendable (e.g., the second portion(s) 154 which may be substantially free of solid-state electrolyte) and segments or portions that are configured to promote high ionic transport (e.g., the first portion(s) 152, for example, having the solid-state electrolyte) between the electrodes.

[0048] Expanding further, in some embodiments, the separators 150 may include a base material, for example, an ion permeable membrane (e.g., PEO, NAFION™, a proton15328896850Agent’s File Ref. 24MT-207 / 01WO 314552-3086conductor, or any of the polymeric materials described herein). The base material may be a porous material that defines a plurality of pores. As previously described herein, the interlayer 160 is disposed between the first separator 150a and the second separator 150b. In some embodiments, the base material of the separators 150 may be reactive with the materials included in the interlayer (e.g., a carbonaceous material) or generally undesirable to be in contact with the interlayer 160. For example, during operation of the electrochemical cell 100, portions of the base material of the separator 150 in contact with the anode 110 and / or the cathode 130 may be susceptible to reacting with the interlayer 160 material, for example, due to liquid electrolyte that may be used to wet the pores of the separators 150 (e.g., the anolyte and / or catholyte). Moreover, a higher voltage (e.g., greater than 3.5 Volts) between the interlayer 160 and anode 110 (or cathode 130) may be used to inhibit dendrite growth (e.g., consume and thus, kill dendrites), which may further increase reactivity of the base material or liquid electrolyte included in the base material with the interlayer 160.

[0049] In some embodiments, to reduce reactivity of the base material of the separators 150 with the interlayer 160, an SSE material (e.g., a sulfide based SSE), or any other suitable material that inhibits reactivity of the described herein may be infused, embedded, or otherwise inserted into the plurality of pores of the base material. The SSE may be substantially less reactive or substantially non-reactive (e.g., have a reactivity of less than 10% relative to the base material), thus inhibiting damage to, and increasing life of the interlayer 160 and hence, the electrochemical cell 100, and may also reduce the voltage used to inhibit dendrite growth (e.g., reduce it to less than or equal to 3.5 V, less than or equal to 3.0 V, less than or equal to 2.5 V, or less than or equal to 2.0 V, inclusive).[0050| While this may be beneficial to conserve integrity of the interlayer 160, the SSE material or any other material disposed in the plurality of pores of the base material may increase the stiffness and / or flexural modulus of the base material, thus reducing bendability of the base material of the separators 150. This can be disadvantageous, for example, if portions of the separators 150 are bended, for example, during packaging or when portions of a single separator layer are included independent stacks of electrochemical cells (e.g., disposed between corresponding cathode and anode pairs). In such cases, bending of the separators 150 including the SSE material may lead to cracking or breaking of the separators 150, or otherwise damage the SSE material.|0051| In some embodiments, to improve electrochemical performance (e.g., reduce reactivity) of portions of the separators 150 that may contact anode 110 and / or cathode 130 of16328896850Agent’s File Ref. 24MT-207 / 01WO 314552-3086the electrochemical cell 100, while maintaining bendability of portions of the separators 150 that do not contact the anode 110 and / or the cathode 130. For example, the first portions 152 of the separators 150 may be configured to contact the anode 110 and / or cathodes 130, therefore, the SSE material or other suitable materials described herein are only incorporated in the first portions 152 (i.e., incorporated only at locations corresponding to the first portions 152 of the base material). In contrast, the SSE material or other suitable materials described herein, are not incorporated in the second portions 154 (i.e., not incorporated in locations corresponding to the second portions 154) such that the second portions 154 only includes the base material. Since the base material generally has a much lower stiffness and flexural modulus, and higher bendability, the second portions 154 maintain their flexibility and can be easily bent relative to the first portions 152. In this manner, the separators 150 described herein incorporate the benefit of reducing reactivity of the separators 150 with interlayer 160 at selected locations (i.e., locations corresponding to first portions 152), while maintaining bendability of the separators 150 at other selected locations (i.e., locations corresponding to second portions 154).

[0052] Accordingly, in some embodiments, the first portion(s) 152 and the second portion(s) 154 may each have a corresponding property (e.g., corresponding material property, mechanical property, or combination thereof). For example, the first portion(s) 152 may have a first property, and the second portion(s) 154 may have a second property. In some embodiments, the first property may be substantially similar to, or the same as, the second property. In some embodiments, the first property may be different than the second property. For example, in some embodiments, the first portion(s) 152 can be configured to remain substantially planar. In some embodiments, the second portion(s) 154 can be configured to bend about an axis.

[0053] In some embodiments, each of the first portion(s) 152 and the second portion(s) 154 may have a corresponding flexural modulus. In some embodiments, the first portion(s) 152 and / or the second portion(s) 154 can have a flexural modulus of at least about 0.01 GPa, at least about 0.1 GPa, at least about 0.5 GPa, at least about 1.0 GPa, at least about 1.5 GPa, at least about 2.0 GPa, at least about 2.5 GPa, at least about 3.0 GPa, at least about 3.5 GPa, at least about 4.0 GPa, at least about 4.5 GPa, at least about 5.0 GPa, at least about 5.5 GPa, at least about 6.0 GPa, at least about 6.5 GPa, at least about 7.0 GPa, at least about 7.5 GPa, at least about 8.0 GPa, at least about 8.5 GPa, at least about 9.0 GPa, at least about 9.5 GPa, at least about 10.0 GPa, at least about 10.5 GPa, at least about 11.0 GPa, at least about 11.5 GPa,17328896850Agent’s File Ref. 24MT-207 / 01WO 314552-3086at least about 12.0 GPa, at least about 12.5 GPa, at least about 13.0 GPa, at least about 13.5 GPa, at least about 14.0 GPa, at least about 14.5 GPa, at least about 15.0 GPa, at least about 15.5 GPa, at least about 16.0 GPa, at least about 16.5 GPa, at least about 17.0 GPa, at least about 17.5 GPa, at least about 18.0 GPa, at least about 18.5 GPa, at least about 19.0 GPa, at least about 19.5 GPa, at least about 20.0 GPa, at least about 20.5 GPa, at least about 21.0 GPa, at least about 21.5 GPa, at least about 22.0 GPa, at least about 22.5 GPa, at least about 23.0 GPa, at least about 23.5 GPa, at least about 24.0 GPa, at least about 24.5 GPa, at least about 25.0 GPa, at least about 25.5 GPa, at least about 26.0 GPa, at least about 26.5 GPa, at least about 27.0 GPa, at least about 27.5 GPa, at least about 28.0 GPa, at least about 28.5 GPa, at least about 29.0 GPa, at least about 29.5 GPa, at least about 30.0 GPa, at least about 30.5 GPa, at least about 31.0 GPa, at least about 31.5 GPa, at least about 32.0 GPa, at least about 32.5 GPa, at least about 33.0 GPa, at least about 33.5 GPa, at least about 34.0 GPa, at least about 34.5 GPa, at least about 35.0 GPa, at least about 35.5 GPa, at least about 36.0 GPa, at least about 36.5 GPa, at least about 37.0 GPa, at least about 37.5 GPa, at least about 38.0 GPa, at least about 38.5 GPa, at least about 39.0 GPa, at least about 39.5 GPa, at least about 40.0 GPa, at least about 40.5 GPa, at least about 41.0 GPa, at least about 41.5 GPa, at least about 42.0 GPa, at least about 42.5 GPa, at least about 43.0 GPa, at least about 43.5 GPa, at least about 44.0 GPa, at least about 44.5 GPa, at least about 45.0 GPa, at least about 45.5 GPa, at least about 46.0 GPa, at least about 46.5 GPa, at least about 47.0 GPa, at least about 47.5 GPa, at least about 48.0 GPa, at least about 48.5 GPa, at least about 49.0 GPa, or at least about 49.5 GPa.|0054| In some embodiments, the first portion(s) 152 and / or the second portion(s) 154 can have a flexural modulus of no more than about 50.0 GPa, no more than about 49.5 GPa, no more than about 49.0 GPa, no more than about 48.5 GPa, no more than about 48.0 GPa, no more than about 47.5 GPa, no more than about 47.0 GPa, no more than about 46.5 GPa, no more than about 46.0 GPa, no more than about 45.5 GPa, no more than about 45.0 GPa, no more than about 44.5 GPa, no more than about 44.0 GPa, no more than about 43.5 GPa, no more than about 43.0 GPa, no more than about 42.5 GPa, no more than about 42.0 GPa, no more than about 41.5 GPa, no more than about 41.0 GPa, no more than about 40.5 GPa, no more than about 40.0 GPa, no more than about 39.5 GPa, no more than about 39.0 GPa, no more than about 38.5 GPa, no more than about 38.0 GPa, no more than about 37.5 GPa, no more than about 37.0 GPa, no more than about 36.5 GPa, no more than about 36.0 GPa, no more than about 35.5 GPa, no more than about 35.0 GPa, no more than about 34.5 GPa, no328896850Agent’s File Ref. 24MT-207 / 01WO 314552-3086more than about 34.0 GPa, no more than about 33.5 GPa, no more than about 33.0 GPa, no more than about 32.5 GPa, no more than about 32.0 GPa, no more than about 31.5 GPa, no more than about 31.0 GPa, no more than about 30.5 GPa, no more than about 30.0 GPa, no more than about 29.5 GPa, no more than about 29.0 GPa, no more than about 28.5 GPa, no more than about 28.0 GPa, no more than about 27.5 GPa, no more than about 27.0 GPa, no more than about 26.5 GPa, no more than about 26.0 GPa, no more than about 25.5 GPa, no more than about 25.0 GPa, no more than about 24.5 GPa, no more than about 24.0 GPa, no more than about 23.5 GPa, no more than about 23.0 GPa, no more than about 22.5 GPa, no more than about 22.0 GPa, no more than about 21.5 GPa, no more than about 21.0 GPa, no more than about 20.5 GPa, no more than about 20.0 GPa, no more than about 19.5 GPa, no more than about 19.0 GPa, no more than about 18.5 GPa, no more than about 18.0 GPa, no more than about 17.5 GPa, no more than about 17.0 GPa, no more than about 16.5 GPa, no more than about 16.0 GPa, no more than about 15.5 GPa, no more than about 15.0 GPa, no more than about 14.5 GPa, no more than about 14.0 GPa, no more than about 13.5 GPa, no more than about 13.0 GPa, no more than about 12.5 GPa, no more than about 12.0 GPa, no more than about 11.5 GPa, no more than about 11.0 GPa, no more than about 10.5 GPa, no more than about 10.0 GPa, no more than about 9.5 GPa, no more than about 9.0 GPa, no more than about 8.5 GPa, no more than about 8.0 GPa, no more than about 7.5 GPa, no more than about 7.0 GPa, no more than about 6.5 GPa, no more than about 6.0 GPa, no more than about 5.5 GPa, no more than about 5.0 GPa, no more than about 4.5 GPa, no more than about 4.0 GPa, no more than about 3.5 GPa, no more than about 3.0 GPa, no more than about 2.5 GPa, no more than about 2.0 GPa, no more than about 1.5 GPa, no more than about 1.0 GPa, no more than about 0.5 GPa, or no more than about 0.1 GPa.

[0055] Combinations of the above-referenced flexural modulus values of the first portion(s) 152 and / or the second portion(s) 154 are also possible (e.g., at least about 0.01 GPa and no more than about 50 GPa, or at least about 0.5 GPa and no more than about 49.5 GPa), inclusive of all values and ranges therebetween. In some embodiments, the first portion(s) 152 and / or the second portion(s) 154 can have a flexural modulus in a range of about 0.01 GPa to about 50.0 GPa, inclusive of all values and ranges therebetween.

[0056] In some embodiments, the first property (i.e., property of the first portion(s) 152) can be a first flexural modulus, and the second property (i.e., property of the second portion(s) 154) can be a second flexural modulus. In some embodiments, the second flexural modulus can be less than the first flexural modulus. In other words, in some embodiments, the first19328896850Agent’s File Ref. 24MT-207 / 01WO 314552-3086flexural modulus (i.e., flexural modulus of the first portions(s) 152) may be greater than the second flexural modulus (i.e., flexural modulus of the second portion(s) 154). In some embodiments, the first portion(s) 152 have a flexural modulus of equal to or greater than about 15 GPa. For example, in some embodiments, the first portion(s) 152 may have a flexural modulus in a range of about 15 GPa to about 50 GPa. In some embodiments, the first portion(s) 152 may have a flexural modulus in a range of about 18 GPa to about 40 GPa. In some embodiments, the second portion(s) 154 may have a flexural modulus of equal to or less than about 14 GPa. For example, in some embodiments, the second portion(s) 154 may have a flexural modulus in a range of about 0.01 GPa to about 14 GPa. In some embodiments, the second portion(s) 154 may have a flexural modulus in a range of about 0.5 GPa to about 5 GPa.

[0057] In some embodiments, each of the first portion(s) 152 and the second portion(s) 154 may have substantially the same elastic modulus. In some embodiments, the first portion(s) 152 and / or the second portion(s) 154 can have an elastic modulus of at least about 0.01 GPa, at least about 0.1 GPa, at least about 0.5 GPa, at least about 1.0 GPa, at least about 1.5 GPa, at least about 2.0 GPa, at least about 2.5 GPa, at least about 3.0 GPa, at least about 3.5 GPa, at least about 4.0 GPa, at least about 4.5 GPa, at least about 5.0 GPa, at least about 5.5 GPa, at least about 6.0 GPa, at least about 6.5 GPa, at least about 7.0 GPa, at least about 7.5 GPa, at least about 8.0 GPa, at least about 8.5 GPa, at least about 9.0 GPa, at least about 9.5 GPa, at least about 10.0 GPa, at least about 10.5 GPa, at least about 11.0 GPa, at least about 11.5 GPa, at least about 12.0 GPa, at least about 12.5 GPa, at least about 13.0 GPa, at least about 13.5 GPa, at least about 14.0 GPa, at least about 14.5 GPa, at least about 15.0 GPa, at least about 15.5 GPa, at least about 16.0 GPa, at least about 16.5 GPa, at least about 17.0 GPa, at least about 17.5 GPa, at least about 18.0 GPa, at least about 18.5 GPa, at least about 19.0 GPa, at least about 19.5 GPa, at least about 20.0 GPa, at least about 20.5 GPa, at least about 21.0 GPa, at least about 21.5 GPa, at least about 22.0 GPa, at least about 22.5 GPa, at least about 23.0 GPa, at least about 23.5 GPa, at least about 24.0 GPa, at least about 24.5 GPa, at least about 25.0 GPa, at least about 25.5 GPa, at least about 26.0 GPa, at least about 26.5 GPa, at least about 27.0 GPa, at least about 27.5 GPa, at least about 28.0 GPa, at least about 28.5 GPa, at least about 29.0 GPa, at least about 29.5 GPa, at least about 30.0 GPa, at least about 30.5 GPa, at least about 31.0 GPa, at least about 31.5 GPa, at least about 32.0 GPa, at least about 32.5 GPa, at least about 33.0 GPa, at least about 33.5 GPa, at least about 34.0 GPa, at least about 34.5 GPa, at least about 35.0 GPa, at least about 35.5 GPa, at least about 36.0 GPa, at least about 36.5 GPa, at least about 37.0 GPa, at least about 37.5 GPa, at least about 38.0 GPa, at20328896850Agent’s File Ref. 24MT-207 / 01WO 314552-3086least about 38.5 GPa, at least about 39.0 GPa, at least about 39.5 GPa, at least about 40.0 GPa, at least about 40.5 GPa, at least about 41.0 GPa, at least about 41.5 GPa, at least about 42.0 GPa, at least about 42.5 GPa, at least about 43.0 GPa, at least about 43.5 GPa, at least about 44.0 GPa, at least about 44.5 GPa, at least about 45.0 GPa, at least about 45.5 GPa, at least about 46.0 GPa, at least about 46.5 GPa, at least about 47.0 GPa, at least about 47.5 GPa, at least about 48.0 GPa, at least about 48.5 GPa, at least about 49.0 GPa, or at least about 49.5 GPa.

[0058] In some embodiments, the first portion(s) 152 and / or the second portion(s) 154 can have an elastic modulus of no more than about 50.0 GPa, no more than about 49.5 GPa, no more than about 49.0 GPa, no more than about 48.5 GPa, no more than about 48.0 GPa, no more than about 47.5 GPa, no more than about 47.0 GPa, no more than about 46.5 GPa, no more than about 46.0 GPa, no more than about 45.5 GPa, no more than about 45.0 GPa, no more than about 44.5 GPa, no more than about 44.0 GPa, no more than about 43.5 GPa, no more than about 43.0 GPa, no more than about 42.5 GPa, no more than about 42.0 GPa, no more than about 41.5 GPa, no more than about 41.0 GPa, no more than about 40.5 GPa, no more than about 40.0 GPa, no more than about 39.5 GPa, no more than about 39.0 GPa, no more than about 38.5 GPa, no more than about 38.0 GPa, no more than about 37.5 GPa, no more than about 37.0 GPa, no more than about 36.5 GPa, no more than about 36.0 GPa, no more than about 35.5 GPa, no more than about 35.0 GPa, no more than about 34.5 GPa, no more than about 34.0 GPa, no more than about 33.5 GPa, no more than about 33.0 GPa, no more than about 32.5 GPa, no more than about 32.0 GPa, no more than about 31.5 GPa, no more than about 31.0 GPa, no more than about 30.5 GPa, no more than about 30.0 GPa, no more than about 29.5 GPa, no more than about 29.0 GPa, no more than about 28.5 GPa, no more than about 28.0 GPa, no more than about 27.5 GPa, no more than about 27.0 GPa, no more than about 26.5 GPa, no more than about 26.0 GPa, no more than about 25.5 GPa, no more than about 25.0 GPa, no more than about 24.5 GPa, no more than about 24.0 GPa, no more than about 23.5 GPa, no more than about 23.0 GPa, no more than about 22.5 GPa, no more than about 22.0 GPa, no more than about 21.5 GPa, no more than about 21.0 GPa, no more than about 20.5 GPa, no more than about 20.0 GPa, no more than about 19.5 GPa, no more than about 19.0 GPa, no more than about 18.5 GPa, no more than about 18.0 GPa, no more than about 17.5 GPa, no more than about 17.0 GPa, no more than about 16.5 GPa, no more than about 16.0 GPa, no more than about 15.5 GPa, no more than about 15.0 GPa, no more than about 14.5 GPa, no more than about 14.0 GPa, no more than about 13.5 GPa, no328896850Agent’s File Ref. 24MT-207 / 01WO 314552-3086more than about 13.0 GPa, no more than about 12.5 GPa, no more than about 12.0 GPa, no more than about 11.5 GPa, no more than about 11.0 GPa, no more than about 10.5 GPa, no more than about 10.0 GPa, no more than about 9.5 GPa, no more than about 9.0 GPa, no more than about 8.5 GPa, no more than about 8.0 GPa, no more than about 7.5 GPa, no more than about 7.0 GPa, no more than about 6.5 GPa, no more than about 6.0 GPa, no more than about 5.5 GPa, no more than about 5.0 GPa, no more than about 4.5 GPa, no more than about 4.0 GPa, no more than about 3.5 GPa, no more than about 3.0 GPa, no more than about 2.5 GPa, no more than about 2.0 GPa, no more than about 1.5 GPa, no more than about 1.0 GPa, no more than about 0.5 GPa, or no more than about 0.1 GPa.

[0059] Combinations of the above-referenced elastic modulus values of the first portion(s) 152 and / or the second portion(s) 154 are also possible (e.g., at least about 0.01 GPa and no more than about 50 GPa, or at least about 0.5 GPa and no more than about 49.5 GPa), inclusive of all values and ranges therebetween. In some embodiments, the first portion(s) 152 and / or the second portion(s) 154 can have a flexural modulus in a range of about 0.01 GPa to about 50.0 GPa, inclusive of all values and ranges therebetween.

[0060] In some embodiments, the first property (i.e., property of the first portion(s) 152) can be a first elastic modulus, and the second property (i.e., property of the second portion(s) 154) can be a second elastic modulus. In some embodiments, the second elastic modulus can be less than the first elastic modulus. In other words, in some embodiments, the first elastic modulus (i.e., elastic modulus of the first portions(s) 152) may be greater than the second elastic modulus (i.e., elastic modulus of the second portion(s) 154). In some embodiments, the first portion(s) 152 have an elastic modulus of equal to or greater than about 15 GPa. For example, in some embodiments, the first portion(s) 152 may have an elastic modulus in a range of about 15 GPa to about 50 GPa. In some embodiments, the first portion(s) 152 may have an elastic modulus in a range of about 18 GPa to about 40 GPa. In some embodiments, the second portion(s) 154 may have an elastic modulus of equal to or less than about 14 GPa. For example, in some embodiments, the second portion(s) 154 may have an elastic modulus in a range of about 0.01 GPa to about 14 GPa, inclusive. In some embodiments, the second portion(s) 154 may have an elastic modulus in a range of about 0.5 GPa to about 5 GPa, inclusive.(0061] In some embodiments, the first portion(s) 152 and / or the second portion(s) 154 can have a porosity of at least about 10%, at least about 15%, at least about 20%, at least about 25%, at least about 30%, at least about 35%, at least about 40%, at least about 45%, at least about 50%, at least about 55%, at least about 60%, at least about 65%, at least about 70%, at22328896850Agent’s File Ref. 24MT-207 / 01WO 314552-3086least about 75%, at least about 80%, at least about 85%, or at least about 90%. In some embodiments, the first portion(s) 152 and / or the second portion(s) 154 can have a porosity of no more than about 95%, no more than about 90%, no more than about 85%, no more than about 80%, no more than about 75%, no more than about 70%, no more than about 65%, no more than about 60%, no more than about 55%, no more than about 50%, no more than about 45%, no more than about 40%, no more than about 35%, no more than about 30%, no more than about 25%, no more than about 20%, or no more than about 15%.

[0062] Combinations of the above-referenced porosity percentages of the first portion(s) 152 and / or the second portion(s) 154 are also possible (e.g., at least about 10% and no more than about 95% or at least about 20% and no more than about 40%), inclusive of all values and ranges therebetween. In some embodiments, the first portion(s) 152 and / or the second portion(s) 154 can have a porosity of about 10%, about 15%, about 20%, about 25%, about 30%, about 35%, about 40%, about 45%, about 50%, about 55%, about 60%, about 65%, about 70%, about 75%, about 80%, about 85%, about 90%, or about 95%.

[0063] In some embodiments, when the first portion(s) 152 includes a solid-state electrolyte, the first portion(s) 152 can have a porosity of at least about 0%, at least about 5%, at least about 10%, at least about 15%, at least about 20%, at least about 25%, at least about 30%, at least about 35%, at least about 40%, at least about 45%, at least about 50%, at least about 55%, at least about 60%, at least about 65%, at least about 70%, at least about 75%, at least about 80%, at least about 85%, or at least about 90%. In some embodiments, when the first portion(s) 152 includes a solid-state electrolyte, the first portion(s) 152 can have a porosity of no more than about 95%, no more than about 90%, no more than about 85%, no more than about 80%, no more than about 75%, no more than about 70%, no more than about 65%, no more than about 60%, no more than about 55%, no more than about 50%, no more than about 45%, no more than about 40%, no more than about 35%, no more than about 30%, no more than about 25%, no more than about 20%, no more than about 15%, no more than about 10%, or no more than about 5%. Combinations of the above-referenced porosities are also possible (e.g., at least about 0% and no more than about 95% or at least about 10% and no more than about 50%), inclusive of all values and ranges therebetween.

[0064] In some embodiments, the porosities of the first portion(s) 152 and / or the second portion(s) can be substantially similar. In some embodiments, the first portion(s) 152 can have a different porosity from the second portion(s) 154. In some embodiments, for example when the first portion(s) 152 include(s) the solid-state electrolyte, the porosity of the first portion(s)23328896850Agent’s File Ref. 24MT-207 / 01WO 314552-3086152 may be lower than the porosity of the second portion(s) 154. Said another way, the second portion(s) 154 may have a porosity greater than that of the first portion(s) 152.

[0065] In some embodiments, the first portion(s) 152 and the second portion(s) 154 can have corresponding ionic conductivities. For example, in some embodiments, the first portion(s) 152 may have a first ionic conductivity. In some embodiments, the second portion(s) 154 may have a second ionic conductivity. In some embodiments, first ionic conductivity (i.e., ionic conductivity of the first portion(s) 152) may be equal to or greater than the second ionic conductivity (i.e., ionic conductivity of the second portion(s) 154). In some embodiments, the ionic conductivity of the first portion(s) 152 may be equal to or greater than about 10'3S / cm. In some embodiments, the ionic conductivity of the first portion(s) 152 may be in a range of about 10'3S / cm to about 10 S / cm. In some embodiments, the ionic conductivity of the second portion(s) 154 may be equal to or less than about 10'3S / cm.

[0066] In some embodiments, the first portion 152a of the first separator 150a may be selected independently from the first portion 152b of the second separator 150b, and hence, the first portion 152a of the first separator 150a and the first portion 152b of the second separator 150b may include or be formed of substantially similar materials, the same materials, or different materials. Likewise, in some embodiments, the second portion 154a of the first separator 150a may be selected independently (e.g., different material) from the second portion 154b of the second separator 150b, and hence, the second portion 154a of the first separator 150a and the second portion 154b of the second separator 150b may include or be formed of similar materials, the same materials, or different materials.

[0067] Although FIG.l depicts the first separator 150a having the first portion 152a and the second portion 154a, along with the second separator 150b having the first portion 152b and the second portion 154b, in some embodiments, each of the first separator 150a and the second separator 150b may include a plurality of distinct portions. For example, each of the first separator 150a and / or the second separator 150b may include the first portion(s) 152 and / or the second portion(s) 154, but the first separator 150a and / or the second separator 150b may include a third portion (not shown), fourth portion (not shown), fifth portion (not shown), sixth portion (not shown), seventh portion (not shown), eighth portion (not shown), ninth portion (not shown), tenth portion (not shown), or greater numbers of portions (not shown), each of which may be distinct or independently selected, and may include or be formed of any of the materials as described with respect to the first portion(s) 152 and / or the second portion(s) 154. Accordingly, each of the first, second, third, fourth, fifth, sixth, seventh, eighth, ninth, tenth24328896850Agent’s File Ref. 24MT-207 / 01WO 314552-3086portions, or greater numbers of portions may have corresponding properties which are distinct or independent from one another (e.g., materials properties, mechanical properties, flexural modulus, elastic modulus, porosity, ionic conductivity, etc.). For example, in some embodiments, the first portion(s) 152 have the first flexural modulus and the second portion(s) 154 have the second flexural modulus, the first flexural modulus greater than the second flexural modulus. Likewise, in some embodiments, the third portion, fourth portion, fifth portion, etc. may have a third flexural modulus, fourth flexural modulus, fifth flexural modulus, etc., respectively. For example, in some embodiments, the separators 150 may include a plurality of first portions 152 including the SSE (e.g., sulfide SSE) or other material that is less reactive to the interlayer 160, and a plurality of second portions 154 that have a higher flexibility or bendability relative to the first portions arranged altematingly, e.g., one after the other, along a length of the separators 150.

[0068] In some embodiments, the first separator 150a can include the first portion 152a and the second portion 154a while the second separator 150b includes the third portion and the fourth portion. In some embodiments, the third portion has a third flexural modulus and / or the fourth portion has a fourth flexural modulus. In some embodiments, the third flexural modulus can be greater than the fourth flexural modulus. In some embodiments, the third flexural modulus can be substantially similar to, or substantially equal to, the first flexural modulus of the first portion(s) 152, and the fourth flexural modulus can be substantially similar to, or substantially equal to, the second flexural modulus of the second portion(s) 154.

[0069] Although FIG.l depicts two separators, i.e., the first separator 150a and the second separator 150b, and a single interlayer 160, in some embodiments, the electrochemical cell 100 can include a plurality of separators 150 and / or a plurality of interlayers 160, each of which may include or be formed of the materials as described with respect to the separator(s) 150 and / or the interlayer 160, respectively, and each of which may include corresponding first portion(s) 152, second portion(s) 154, or greater numbers of portions, each of which may be distinct or independent and may include or be formed of the materials as described with respect to the first portion(s) 152 or the second portion(s) 154.

[0070] In some embodiments, the first separator 150a, the second separator 150b, and interlayer 160 may be used in a separator assembly configured to separate a plurality of electrodes disposed in an electrochemical cell stack. For example, in some embodiments, electrochemical cell 100 may include a plurality of anodes (e.g., anode 110), anode current collectors (e.g., anode current collector 120), cathodes (e.g., cathode 130), and / or cathode25328896850Agent’s File Ref. 24MT-207 / 01WO 314552-3086current collectors (e.g., cathode current collector 140) in a stack configuration, and the separator assembly may be disposed between each corresponding anode-cathode pair, for example, to provide electrical insulation / isolation between the anode(s) 110 and cathode(s) 130 while enabling ions to pass therebetween. In some embodiments, the separator assembly may be disposed in a serpentine configuration between each anode-cathode pair, for example, with the first portion(s) 152 being substantially planar (or configured to be substantially planar) and disposed on at least one of the anode(s) HOand / orthe cathode(s) 130, and the second portion(s) 154 being bent (or configured to bend) such that the separator assembly may have substantially planar portions between the electrodes and bent portions proximate an end of the electrodes. In some embodiments, the first portion(s) 152 may include the solid-state electrolyte such that cell has segments, regions, or areas of increased ion transport between the anode 110 and the cathode 130. In some embodiments, the second portion(s) 154 do not include the solid-state electrolyte, such that the second portion may be configured to bend as needed to utilize space effectively in the cell 100.(0071 ] The interlayer 160 can dissolve dendrites via voltage manipulation. In other words, current can be supplied to the interlayer 160, the anode 110, and / or the cathode 130 to create a potential difference between the interlayer 160 and the anode 110 or the interlayer 160 and the cathode 130 that dissolves dendrites that have formed in the interlayer 160. In some embodiments, the interlayer 160 can include a conductive layer. In some embodiments, the interlayer 160 can include a liquid electrolyte. In some embodiments, the interlayer 160 can include a solid-state electrolyte. In some embodiments, the interlayer 160 can include a carbonaceous material such as carbon black, KETJEN BLACK™, AA-stacked graphene, AB-stacked graphene, carbon, hard carbon, soft carbon, graphite, lithium iron phosphate (LFP), lithium manganese iron phosphate (LMFP), lithium manganese oxide (LMO), LiNiCh (LNO), nickel manganese cobalt (NMC), lithium nickel manganese oxide (LNMO), lithium cobalt oxide (LCO), Iron (III) fluoride (FeFs), sulfur, vanadium (V) oxide (V2O5), bismuth trifluoride (BiFs), iron (IV) sulfate (FeS2), or any combination thereof. In some embodiments, the interlayer 160 can create a physical block that prevents vertical growth of the dendrite, such that the dendrite is forced to grow horizontally.

[0072] In some embodiments, the interlayer 160 can include an intercalate cathode (e.g., LMOP, LNO, NMC, LFP, LNMO, LCO, and / or LMFP). In some embodiments, the interlayer 160 can include a convertible cathode (e.g., FeFs, sulfur, V2O5, BiFs, FeS2). In some embodiments, the interlayer 160 can include a high voltage bearable anode. In some26328896850Agent’s File Ref. 24MT-207 / 01WO 314552-3086embodiments, the interlayer 160 can include a traditional anode (e.g., hard carbon, graphite, and / or silicon). In some embodiments, the interlayer 160 can include a metal. In some embodiments, the interlayer 160 can include a metal alloy. In some embodiments, the metal alloy can include lithium, tin, aluminum, silver, and / or copper. In some embodiments, the interlayer 160 can include a metal oxide. In some embodiments, the metal oxide can include silicon oxide (SiO), zinc oxide (ZnO), copper oxide (C112O), lithium titanate (LTO), and / or titanium (IV) oxide (TiCh). In some embodiments, the interlayer 160 can include a semi-solid electrode. In some embodiments, the interlayer 160 can include a coating, a spray, and / or a print polymer. In some embodiments, the interlayer 160 can include a ceramic powder. In some embodiments, the interlayer 160 can include a premade film with a solid-state electrolyte.

[0073] In some embodiments, the interlayer 160 can include conductive materials. In some embodiments, the interlayer 160 can include allotropes of carbon including activated carbon, hard carbon, soft carbon, KETJEN BLACK™ (e.g., conductive carbon particles), carbon black, graphitic carbon, carbon fibers, carbon microfibers, vapor-grown carbon fibers (VGCF), fullerenic carbons including “buckyballs”, carbon nanotubes (CNTs), multiwall carbon nanotubes (MWNTs), single wall carbon nanotubes (SWNTs), graphene, graphene sheets or aggregates of graphene sheets, and materials comprising fullerenic fragments, or any combination thereof. In some embodiments, the interlayer 160 can include a solid-state electrode material. In some embodiments, the solid-state electrolyte can include an oxidebased electrolyte. In some embodiments, the solid-state electrolyte material can include lithium lanthanum zirconium oxide (LLZO), Lii.3Alo.3Tii.7(P04)3 (LATP), lithium phosphorus oxynitride (LiPON), li-ion conducting solid-state electrolyte ceramics (LLTO), and / or LiiBOi-Li2SO4-Li2CO3 (LiBSCO). In some embodiments, the solid-state electrolyte material can include one or more oxide-based solid electrolyte materials including a garnet structure, a perovskite structure, a phosphate-based Lithium Super Ionic Conductor (LISICON) structure, a glass structure such as Lao.51Lio.34TiO2.94, Lii.3Alo.3Tii.7(P04)3, Lii.4Alo.4Tii.6(P04)3, Li7La3Zr20i2, Li6.66La3Zn.6Tao.40i2.9 (LLZO), 50Li4Si04*50Li3B03, Li2.9PO3.3N0.46 (lithium phosphorousoxynitride, LiPON), Li3.6Sio.6Po.4O4, Li3BN2, Li3BO3-Li2SO4, and / or sulfide containing solid electrolyte materials including a thio-LISICON structure, a glassy structure and a glass-ceramic structure such as Lii.o7Alo.69Tii.46 P04)3, Lii.5Alo.5Gei.5(P04)3, LiioGeP2Si2 (LGPS), 30Li2S«26B2S3’44LiI, 63Li2S«36SiS2«lLi3PO4, 57Li2S«38SiS2«5Li4SiO4, 70Li2S*30P2S5, 50Li2S*50GeS2, Li7P3Sn, Li3.25P0.95S4, and Li9.54Sii.74Pi.44Sn.7Clo.3, and / or closo-type complex hydride solid electrolyte, LiBEL-Lil, LiBEh-LiNFb, LiBELJhSs,27328896850Agent’s File Ref. 24MT-207 / 01WO 314552-3086Li(CBxHx+i)-LiI, Li(CB9Hio)-and / or Lil. In some embodiments, the solid-state electrolyte material can be sulfide-based. In some embodiments, the solid-state electrolyte can include lithium phosphorus sulfide (LPS), LiioGeP2Si2 (LGPS), lithium tin phosphorus sulfide (LSPS), and / or Lis.sPS^sCli.s (LPSCI) and / or lithium argyrodite LiePSsX (X= Cl, Br) and / or halide electrolytes Lis-xMi-xXe (M = Y, Er, In, Yb, Ho, X= Cl, Br, I, F). In some embodiments, the solid-state electrolyte material can include a complex hydride solid electrolyte. In some embodiments, the solid-state electrolyte material can include LiBHi-Lil and / or LiBH4-P2Ss.

[0074] In some embodiments, when the interlayer 160 includes a solid-state electrolyte, the interlayer 160 can have a porosity of at least about 0%, at least about 5%, at least about 10%, at least about 15%, at least about 20%, at least about 25%, at least about 30%, at least about 35%, at least about 40%, at least about 45%, at least about 50%, at least about 55%, at least about 60%, at least about 65%, at least about 70%, at least about 75%, at least about 80%, at least about 85%, or at least about 90%. In some embodiments, when the interlayer 160 includes a solid-state electrolyte, the interlayer 160 can have a porosity of no more than about 95%, no more than about 90%, no more than about 85%, no more than about 80%, no more than about 75%, no more than about 70%, no more than about 65%, no more than about 60%, no more than about 55%, no more than about 50%, no more than about 45%, no more than about 40%, no more than about 35%, no more than about 30%, no more than about 25%, no more than about 20%, no more than about 15%, no more than about 10%, or no more than about 5%. Combinations of the above-referenced porosities are also possible (e.g., at least about 0% and no more than about 95% or at least about 10% and no more than about 50%), inclusive of all values and ranges therebetween. In some embodiments, when the interlayer includes a solid-state electrolyte, the interlayer 160 can have a porosity of about 0%, about 5%, about 10%, about 15%, about 20%, about 25%, about 30%, about 35%, about 40%, about 45%, about 50%, about 55%, about 60%, about 65%, about 70%, about 75%, about 80%, about 85%, about 90%, or about 95%.

[0075] In some embodiments, when the interlayer 160 includes a liquid electrolyte, the interlayer 160 can have a porosity of at least about 10%, at least about 15%, at least about 20%, at least about 25%, at least about 30%, at least about 35%, at least about 40%, at least about 45%, at least about 50%, at least about 55%, at least about 60%, at least about 65%, at least about 70%, at least about 75%, at least about 80%, at least about 85%, or at least about 90%. In some embodiments, when the interlayer 160 includes a liquid electrolyte, the interlayer 160 can have a porosity of no more than about 95%, no more than about 90%, no more than about28328896850Agent’s File Ref. 24MT-207 / 01WO 314552-308685%, no more than about 80%, no more than about 75%, no more than about 70%, no more than about 65%, no more than about 60%, no more than about 55%, no more than about 50%, no more than about 45%, no more than about 40%, no more than about 35%, no more than about 30%, no more than about 25%, no more than about 20%, or no more than about 15%. Combinations of the above-referenced porosities are also possible (e.g., at least about 0% and no more than about 95% or at least about 10% and no more than about 50%), inclusive of all values and ranges therebetween. In some embodiments, when the interlayer includes a liquid electrolyte, the interlayer 160 can have a porosity of about 10%, about 15%, about 20%, about 25%, about 30%, about 35%, about 40%, about 45%, about 50%, about 55%, about 60%, about 65%, about 70%, about 75%, about 80%, about 85%, about 90%, or about 95%.

[0076] In some embodiments, the interlayer 160 can be pre-coated onto the first separator 150a and / or the second separator 150b. In some embodiments, the interlayer 160 can aid in identifying a contamination amount of lithium (e.g., due to dendrite growth) or another metal via a controller 170. The controller 170 can then add more voltage and current to the interlayer 160 to dissolve the contamination (e.g., dissolve or consume dendrites). The controller 170 can keep the state of charge (SOC) of the interlayer 160 between a lower bound (e.g., about 10%, about 15%, about 20%, about 25%, about 30%, about 35%, or about 40%, inclusive of all values and ranges therebetween) and an upper bound (e.g., about 60%, about 65%, about 70%, about 75%, about 80%, about 85%, or about 90%, inclusive of all values and ranges therebetween). Keeping the interlayer 160 between a lower bound and an upper bound of voltage can aid in diminishing dendrite formation while the electrochemical cell 100 is not in use (e.g., via addition of voltage and / or current). In some embodiments, the interlayer 160 can include a tab (not shown) that can be used to monitor the voltage of the interlayer 160 while the electrochemical cell is hot pressed (e.g., via a two-sided hot press or a four-sided hot press with a jelly roll design to fit into a prismatic can). In some embodiments, the tab can extend from the interlayer 160. In some embodiments, the tab can extend beyond at least one of the first separator 150a or the second separator 150b. In some embodiments, the tab can be uncoated, as coating the tab with sulfide or SSE can create adhesion problems.10077] FIG. 2 is a schematic illustration of an electrochemical cell 200 including an interlayer 260 in a substantially planar configuration, according to an embodiment. As shown, the electrochemical cell 200 includes an anode 210 disposed on an anode current collector 220, and a cathode 230 disposed on a cathode current collector 240. The electrochemical cell 200 further includes a plurality of separators 250a, 250b (collectively referred to herein as29328896850Agent’s File Ref. 24MT-207 / 01WO 314552-3086“separator(s) 250”). The interlayer 260 is disposed between the separators 250. In some embodiments, the separators 250 and the interlayer 260 may be collectively referred to herein as a separator assembly 255. The first separator 250a includes first portions 252al, 252a2, and a second portion 254a. The second separator 250b further includes first portions 252b 1, 252b2, and a second portion 254b.

[0078] In some embodiments, the first portions 252al, 252a2 of the first separator 250a may be distinct from (e.g., independent from, selected independently from), the same as, or substantially similar to, the first portions 252bl, 252b2 of the second separator 250b. The first portions 252al, 252a2, 252b 1, 252b2 are collectively referred to herein as first portion(s) 252.

[0079] In some embodiments, the second portion 254a of the first separator 250a may be distinct from (e.g., independent from, selected independently from), the same as, or substantially similar to, the second portion 254b of the second separator 250b. The second portions 254a, 254b may be collectively referred to herein as second portion(s) 254.10080] In some embodiments, the electrochemical cell 200, the anode 210, the anode current collector 220, the cathode 230, the cathode current collector 240, the separator(s) 250, the first portion(s) 252, the second portion(s) 254, and / or the interlayer 260 may be the same as, or substantially similar to, the electrochemical cell 100, the anode 110, the anode current collector 120, the cathode 130, the cathode current collector 140, the separator(s) 150, the first portion(s) 152, the second portion(s) 154, and / or the interlayer 160, respectively, as previously described with respect to FIG. 1. Therefore, certain features of the electrochemical cell 200, the anode 210, the anode current collector 220, the cathode 230, the cathode current collector 240, the separator(s) 250, the first portion(s) 252, the second portion(s) 254, and / or the interlayer 260 are not described in further detail herein.

[0081] In some embodiments, the first portion(s) 252 may include, or be formed substantially of, solid-state electrolyte materials. In some embodiments, the second portion(s) 254 can include, or be formed substantially of conventional separator materials. In some embodiments, the second portion(s) 254 can be substantially free of solid-state electrolyte. In some embodiments, the second portion(s) 254 do not include the solid-state electrolyte.

[0082] Without being bound by theory, including the SSE material in the first portion(s) 252 of the separators 250 can improve ionic conductivity between the anode 210 and the cathode 230 over conventional separator materials. However, doing so may increase the stiffness or rigidity of the first portion(s) 252 of the separators 250 over other portion(s) of the30328896850Agent’s File Ref. 24MT-207 / 01WO 314552-3086separator(s) 250 that are free, or substantially free, of the solid-state electrolyte. Therefore, in some embodiments, it may be advantageous to include the second portion(s) 254 of the separators 250, which are substantially free of, or do not include, the solid-state electrolyte. Without being bound by theory, separators 250 including the second portion(s) 254, which may be substantially free of solid-state electrolyte, may impart flexibility to the separators 250 and / or the electrochemical cell 200, for example, at least the second portion(s) 254 of the separators 250. This may, for example, enable separator(s) 250 (or separator assemblies 255) that are multi-functional and including segments or portions that are bendable or flexible (e.g., the second portion(s) 254, which may be substantially free of solid-state electrolyte), and segments or portions that are configured to promote high ionic transport (e.g., the first portion(s) 252, for example, having the solid-state electrolyte) between the electrodes (e.g., anode 210, cathode 230).|0083| In some embodiments, the electrochemical cell 200, for example, including separators 250 with first portion(s) 252, may be configured to have, or may have, high ionic transport properties between electrodes (e.g., anode 210, cathode 230) in predetermined locations. For example, in some embodiments, the electrochemical cell 200 may have high ionic transport properties proximate the first portion(s) 252.[0084) Although the electrochemical cell 200 as shown in FIG. 2 is substantially planar, in some embodiments, the electrochemical cell 200 and / or the separator assembly 255 (e.g., including separators 250, first portion(s) 252, second portion(s) 254, and / or the interlayer 260), may be configured to bend, or may bend, in predetermined location(s), such as at, or proximate, the second portion(s) 254.[0085| For example, FIG. 3 is a schematic illustration of a separator assembly 355 in a folded configuration, according to an embodiment. As shown, the separator assembly 355 includes a first separator 350a and a second separator 350b (collectively referred to herein as “separators 350”). The separator assembly 355 further includes an interlayer 360 disposed between separators 350. The separator assembly 355 further includes first portions 352al, 352a2, 352a3 incorporated (e.g., disposed) in the first separator 350a, and first portions 352bl, 352b2, 352b3 incorporated in the second separator 350b. The separator assembly 355 further includes second portions 354al, 354a2 incorporated in the first separator 350a, and second portions 354bl, 354b2, incorporated in the second separator 350b.31328896850Agent’s File Ref. 24MT-207 / 01WO 314552-3086|0086] In some embodiments, the first portions 352al, 352a2, 352a3 of the first separator 350a may be distinct from (e.g., independent from, selected independently from), the same as, or substantially similar to, the first portions 352bl, 352b2, 352b3 of the second separator 350b. The first portions 352al, 352a2, 352a3, 352bl, 352b2, 352b3 may be collectively referred to herein as “first portion(s) 352”. Likewise, in some embodiments, the second portions 354al, 354a2 of the first separator 350a may be distinct from (e.g., independent from, selected independently from), the same as, or substantially similar to, the second portions 354bl, 354b2 of the second separator 350b. The second portions 354al,354a2, 354bl, 354b2 may be collectively referred to herein as “second portion(s) 354”.

[0087] In some embodiments, the separators 350, the first portion(s) 352, the second portion(s) 354, and / or the interlayer 360 may be the same as, or substantially similar to, the separators 150, 250 the first portion(s) 152, 252, the second portion(s) 154, 254, and / or the interlayer 160, 260 respectively, of the electrochemical cell 100, 200, as previously described with respect to FIGS. 1 and 2. Therefore, certain features of the separators 350, the first portion(s) 352, the second portion(s) 354, and / or the interlayer 360 are not described in further detail herein.

[0088] As shown in FIG. 3, in some embodiments, the first portion(s) 352 may be substantially planar. The first portion(s) 352 (i.e., substantially planar portions) may be disposed between electrodes (e.g., anode 110, cathode 130 of FIG. 1) and configured to electrically separate (e.g., isolate) the electrodes (e.g., anode 110, cathode 130 of FIG. 1). In some embodiments, the first portion(s) 352 may include, or may be formed substantially of, an ionically permeable membrane, for example, to facilitate transfer of ions between the electrodes (e.g., anode 110, cathode 130 of FIG. 1). In some embodiments, the first portion(s) 352 may include ionically conductive materials, for example, incorporated therein or disposed (e.g., coated) thereon. In some embodiments, the first portion(s) 352 may be rigid. In some embodiments, the first portion(s) 352 may include a rigid material incorporated therein or disposed (e.g., coated) thereon. In some embodiments, the first portion(s) 352 may incorporate (e.g., be embedded with, be coated with) an SSE. The SSE may be the same as, or substantially similar to, the solid-state electrolytes as described with respect to FIG. 1. In some embodiments, first portion(s) 352 including the solid-state electrolyte may enable the separator(s) 350 and / or separator assembly 355 to have improved rate capabilities (e.g., ionic transfer rate, charge rates, discharge rates), or regions of improved rate capabilities, between32328896850Agent’s File Ref. 24MT-207 / 01WO 314552-3086electrodes (e.g., anode 110, cathode 130 of FIG. 1) over conventional separators or assemblies of conventional separator materials.

[0089] As shown in FIG. 3, in some embodiments, the second portion(s) 354 may be bent, or include bend points, to facilitate folding of the separator assembly 355. In some embodiments, the second portion(s) 354 may flexible, or formed of flexible materials. Including the second portion(s) 354 in the separator assembly 355 may enable the separator assembly 355 to be disposed in many electrochemical cells (e.g., electrochemical cell 100 of FIG. 1) with various geometries while reducing the amount of unused (or inactive) space in the electrochemical cells (e.g., electrochemical cell 100 of FIG. 1). In some embodiments, the second portion(s) 354 may be configured to electrically separate the electrodes (e.g., anode 110, cathode 130 of FIG. 1). In some embodiments, the second portion(s) 354 may be configured to fluidically isolate the electrodes. In some embodiments, the first portion(s) 352 may have a higher bendability about a bend axis relative to the second portion(s) 354.

[0090] As shown in FIG. 3, in some embodiments, each of the first portion(s) 352 and the second portion(s) 354 may include corresponding axial ends. In some embodiments, axial end(s) of the first portion(s) 352 may be coupled to axial end(s) of the second portion(s) 354.

[0091] Although FIG. 3 depicts clear boundaries between the first portion(s) 352 and the second portion(s) 354, in some embodiments, the separator(s) 350 including the first portion(s) 352 and the second portion(s) 354 may be formed (e.g., extruded) from a continuous piece of material. In some embodiments, the separator(s) 350 may incorporate SSE in regions thereof (e.g., first portion(s) 352) and may be substantially free of solid-state electrolyte in other regions thereof (e.g., second portion(s) 354). For example, in some embodiments, while incorporating the SSE into the separator(s) 350, portions may be masked (e.g., covered, blocked) to form the second portion(s) 354 that are substantially free of solid-state electrolyte, and portions may be unmasked (e.g., uncovered, unblocked) to form the first portion(s) 352 including the SSE.

[0092] In some embodiments, the separator(s) 350 can include a gradient (e.g., single modal, bi-modal, multi-modal gradient) of the SSE concentration. For example, in some embodiments, the separator(s) 350 include a concentration of SSE material(s) throughout the separator(s) 350. In some embodiments, the concentration of the SSE is higher in the first portion(s) 352 than in the second portion(s) 354. In some embodiments, the concentration of SSE may be substantially, or significantly, higher in the first portion(s) 352 than in the second33328896850Agent’s File Ref. 24MT-207 / 01WO 314552-3086portion(s) 352 (e.g., greater than 10X, greater than 20X, greater than 30X, greater than 40X, greater than 50X, greater than 60X, greater than 70X SSE, greater than 80X, greater than 90X, or greater than 100X in the first portion(s) 352 relative to the second portion(s) 354). In some embodiments, the concentration of SSE may remain substantially consistent along a length of the first portion(s) 352 until reaching a location proximate, or at a boundary of, the second portion(s) 354 in which the concentration of SSE may decrease substantially or significantly (e.g., dramatically decrease). In some embodiments, each of the second portion(s) 354 includes a center (e.g., midpoint, inflection point, arc center) of the bend, which may represent or coincide with a bend axis of the bend. In some embodiments, the second portion(s) 354 are substantially free of, or do not include any, SSE proximate the center of second portion(s) 354. In some embodiments, the second portion(s) 354 remain substantially free of SSE along an entire length of the second portion(s) 354.|0093| Although, each of the separator(s) 350 is shown as having three planar portions (e.g., first portions 352al, 352a2, 352a3 of separator 350a, or first portions 352bl, 352b2, 352b3 of separator 350b) and two bent portions (e.g., second portion(s) 354al, 354a2 of the separator 350a, or second portion(s) 354bl, 354b2 of the second separator 350b), in some embodiments, each of the separator(s) 350 may include an even greater numbers of first portion(s) 352 and / or second portion(s) 354. For example, in some embodiments, the separator(s) 350 may include at least about 2, at least about 3, at least about 4, at least about 5, at least about 6, at least about 7, at least about 8, at least about 9, at least about 10, at least about 11, at least about 12, at least about 13, at least about 14, at least about 15, at least about 16, at least about 17, at least about 18, at least about 19, at least about 20, or even greater numbers of first portion(s) 352 and / or second portion(s) 354. In some embodiments, the separator(s) 350 may include no more than about 20, no more than about 19, no more than about 18, no more than about 17, no more than about 16, no more than about 15, no more than about 14, no more than about 13, no more than about 12, no more than about 10, no more than about 9, no more than about 8, no more than about 7, no more than about 6, no more than about 5, no more than about 4, no more than about 3, or no more than about 2 first portion(s) 352 and / or second portion(s) 354. In some embodiments, combinations of the above referenced numbers of first portion(s) 352 and / or second portion(s) 354 for the separator(s) 350 are also possible (e.g., at least about 2 and no more than about 20, or at least about 3 and no more than about 16), inclusive of all values and ranges therebetween. In some embodiments, the separator(s) 35034328896850Agent’s File Ref. 24MT-207 / 01WO 314552-3086may include an even number of first portion(s) 352 and an odd number of second portion(s) 354 or vice versa.

[0094] In some embodiments, including greater numbers of second portion(s) 354 may enable stacks of electrochemical cells having multiple electrodes (e.g., anode 110, cathode 130 of FIG. 1) with the separator assembly 355 being a continuous separator assembly 355 disposed between electrodes, for example, in a “serpentine” configuration. Incorporating multiple second portion(s) 354 in the separator assembly 355 enables the continuous separator assembly 355 to bend as needed (e.g., at locations corresponding to one or more second portion(s) 354) to enable electrical isolation between multiple electrode pairs (e.g., anode 110, cathode 130) while enabling ionic transfer between multiple ionic pairs (e.g., anode 110, cathode 130). Alternatively, in some embodiments, including greater numbers of first portion(s) 352 in the separator assembly 355 may, for example, help improve overall conductivity of the separator(s) 350, separator assembly 355, and / or of electrochemical cells (e.g., electrochemical cell 100 of FIG. 1) or electrochemical cell stacks (e.g., electrochemical cell assemblies) including the separator assembly 355.

[0095] FIG. 4 is a schematic illustration of an electrochemical cell assembly 400 including a separator assembly 455 with an interlayer 460, according to an embodiment. The electrochemical cell assembly 400 includes a first anode 410a disposed on a first anode current collector 420a, a second anode 410b disposed on a second anode current collector 420b, and a third anode 410c disposed on a third anode current collector 420c. The electrochemical cell assembly 400 further includes a first cathode 430a disposed on a first cathode current collector 440a, a second cathode 430b disposed on a second cathode current collector 440b, and a third cathode 430c disposed on a third cathode current collector 440c. The electrochemical cell assembly 400 further includes the separator assembly 455 including a first separator 450a, a second separator 450b, and the interlayer 460 disposed between the first separator 450a and the second separator 450b. The first separator 450a includes first portions 452al, 452a2, 452a3, 452a4, 452a5 and second portions 454al, 454a2, 454a3, 454a4. The second separator 450b includes first portions 452bl, 452b2, 452b3, 452b4, 452b5 and second portions 454bl, 454b2, 454b3, 454b4. Each anode 410a, 410b, 410c, and corresponding cathode 430a, 430b, 430c pair with a portion of the separator assembly 455 disposed therebetween may include or represent an individual electrochemical cell included in the electrochemical cell assembly 400.

[0096] In some embodiments, the first anode 410a, the second anode 410b, and / or the third anode 410c may be distinct (e.g., independent, selected independently) from one another. In35328896850Agent’s File Ref. 24MT-207 / 01WO 314552-3086some embodiments, the first anode 410a, the second anode 410b, and the third anode 410c may be the same, or substantially similar to one another. The first anode 410a, the second anode 410b, and the third anode 410c are collectively referred to herein as “anode(s) 410”. Likewise, in some embodiments, the first anode current collector 420a, the second anode current collector 420b, and / or the third anode current collector 420c may be distinct (e.g., independent, selected independently) from one another. In some embodiments, the first anode current collector 420a, the second anode current collector 420b, and the third anode current collector 420c may be the same, or substantially similar to one another. The first anode current collector 420a, the second anode current collector 420b, and the third anode current collector 420c are collectively referred to herein as “anode current collector(s) 420”.

[0097] In some embodiments, the first cathode 430a, the second cathode 430b, and / or the third cathode 430c may be distinct (e.g., independent, selected independently) from one another. In some embodiments, the first cathode 430a, the second cathode 430b, and the third cathode 430c may be the same, or substantially similar to one another. The first cathode 430a, the second cathode 430b, and the third cathode 430c are collectively referred to herein as “cathodes(s) 430”. Likewise, in some embodiments, the first cathode current collector 440a, the second cathode current collector 440b, and / or the third cathode current collector 440c may be distinct (e.g., independent, selected independently) from one another. In some embodiments, the first cathode current collector 440a, the second cathode current collector 440b, and the third cathode current collector 440c may be the same, or substantially similar to one another. The first cathode current collector 440a, the second cathode current collector 440b, and the third cathode current collector 440c are collectively referred to herein as “cathode current collector(s) 440”.

[0098] In some embodiments the first portions 452a 1, 452a2, 452a3, 452a4, 452a5 of the first separator 450a may be distinct from (e.g., independent from, selected independently from), the same as, or substantially similar to, the first portions 452bl, 452b2, 452b3, 452b4, 452b5 of the separator 450a. The first portions 452al, 452a2, 452a3, 452a4, 452a5, 452bl, 452b2, 452b3, 452b4, 452b5 are collectively referred to herein as “first portion(s) 452”. Likewise, in some embodiments, the second portions 454al, 454a2, 454a3, 454a4 of the first separator 450a may be distinct from (e.g., independent from, selected independently from), the same as, or substantially similar to, the second portions 454bl, 454b2, 454b3, 454b4 of the second separator 450b. The second portions 454al, 454a2, 454a3, 454a4, 454bl, 454b2, 454b3, 454b4 are collectively referred to herein as “second portion(s) 454”. Furthermore, the first separator36328896850Agent’s File Ref. 24MT-207 / 01WO 314552-3086450a may be the same as, or substantially similar to, the second separator 450b. The first separator 450a and the second separator 450b are collectively referred to herein as “separator(s) 450”.

[0099] In some embodiments, the electrochemical cell assembly 400, the anode(s) 410, the anode current collector(s) 420, the cathode(s) 430, the cathode current collector(s) 440, the separator(s) 450, the first portion(s) 452, the second portion(s) 454, and / or the interlayer 460 may be the same as, or substantially similar to, the electrochemical cell 100, 200, the anode 110, 210, the anode current collector 120, 220, the cathode 130, 230, the cathode current collector 140, 240, the separator(s) 150, 250, 350, the first portion(s) 152, 252, 352, the second portion(s) 154, 254, 354, and / or the interlayer 160, 260, 360, respectively, as previously described with respect to FIGS. 1, 2, and 3. Therefore, certain features of the electrochemical cell assembly 400, the anode(s) 410, the anode current collector(s) 420, the cathode(s) 430, the cathode current collector(s) 440, the separator assembly 455, the separator(s) 450, the first portion(s) 452, the second portion(s) 454, and / or the interlayer 460 are not described in further detail herein.

[0100] In some embodiments, the separator assembly 455 may include substantially planar portion(s), for example, disposed between each of corresponding pair of anodes 410 and cathode(s) 430. For example, as shown, the first portion(s) 452 may be substantially planar. In some embodiments, the first portion(s) 452 may be interposed between each corresponding pair of anode(s) 410 and cathode(s) 430. The first portion(s) 452 may be configured to provide electrical isolation and / or high rate capabilities between each corresponding pair of anodes 410 and cathode(s) 430.

[0101] As shown, the separator assembly 455, including the separator(s) 450, first portion(s) 452, second portion(s) 454, and interlayer 460, may be continuous or semi-continuous. In some embodiments, the continuous or semi-continuous separator assembly 455 may be folded, or bent, at predetermined location(s). For example, the separator assembly 455 may be folded, or bent, at or proximate to the second portion(s) 454. In this manner, the separator(s) 450 and / or the separator assembly 455 may reduce, or be configured to reduce, an inactive space in the electrochemical cell assembly 400. This may, for example, enable the electrochemical cell assembly 400 to have a high space efficiency and / or a higher ratio of active to inactive materials incorporated therein as compared with electrochemical cell assemblies with conventional separators.37328896850Agent’s File Ref. 24MT-207 / 01WO 314552-3086

[0102] The interlayer 460, may be disposed between the separator(s) 450. In some embodiments, the interlayer 460 may include planar portions disposed between each corresponding pair of anodes 410 and cathodes 430. In some embodiments, the interlayer 460 may include non-planar portions. In some embodiments, the interlayer 460 may be folded, or bent, and include portions disposed between the second portion(s) 454. The interlayer 460 may include, be coated with, or be formed substantially of, a conductive material (e.g., electrically conductive material). The conductive materials included in the interlayer 460 may be the same, or substantially similar to, the conductive materials included in the interlayer 160, as previously described with respect to FIG. 1.

[0103] Although, not shown in FIG. 4, in some embodiments, the interlayer 460 may extend beyond at least one of the separator(s) 450. In some embodiments, the interlayer 460 may include a tab (not shown), for example, coated with an electrically conductive material, the tab extending beyond at least one of the separator(s) 450. In some embodiments, the interlayer 460 may be coupled to an external device or casing in which the electrochemical cell assembly 400 is disposed, for example, in embodiments in which the interlayer 460 (or the tab) extends beyond at least one of the separator(s) 450.

[0104] In some embodiments, the electrochemical cell assembly 400 may include, or may be electrically coupled to, a power source (not shown), and / or a voltage monitoring system (not shown) (e.g., the controller 170 shown in FIG. 1). For example, in some embodiments, the anode(s) 410, the anode current collector(s) 420, the cathode(s) 430, the cathode current collector(s) 440, and / or the interlayer 460, may be electrically coupled to the power source and / or the voltage monitoring system. In some embodiments, the voltage monitoring system may be configured to detect dendrite formation or growth, for example, in the anode(s) 410. In some embodiments, the interlayer 460 may be configured to receive electrical energy from the power source. In some embodiments, the power source may be configured to transfer electrical energy between at least one of the anode(s) 410 or cathode(s) 430 and the interlayer 460. In some embodiments, the power source may be in communication with the voltage monitoring system, for example, via a controller (not shown) and / or a network (not shown), such that the voltage monitoring system may be configured to detect dendrite growth or formation and instruct, via the controller, the power source to transfer energy to or from the interlayer 460. In some embodiments, the interlayer 460 may be configured to receive the electrical energy transferred from the anode(s) 410 or the cathode(s) 430, for example, via the power source. In some embodiments, the power source may be configured to maintain a38328896850Agent’s File Ref. 24MT-207 / 01WO 314552-3086voltage between interlayer 460 and at least one of the anode(s) 410 or the cathode(s) 430 above a threshold value. In some embodiments, the power source may be configured to maintain the voltage between interlayer 460 and at least one of the anode(s) 410 or the cathode(s) 430 below a threshold value. The electrochemical cell assembly 400 including the separator assembly 455 and / or interlayer 460 as described herein may inhibit dendrite formation and / or growth, which substantially reduces the risk of electrical shorts, thermal runaway, and / or other associated safety hazards (e.g., fires). This may, for example, enable the electrochemical cell assembly 400 to have substantially increased safety (and / or substantially reduced risks of safety hazards) over conventional electrochemical cells and / or conventional electrochemical cell assemblies.

[0105] Accordingly, the electrochemical cells (e.g., 100, 200) and / or electrochemical cell assemblies (e.g., 400) as described herein including the separator assemblies (e.g., 255, 355, 455), separator(s) (e.g., 150, 250, 350, 450) with first portion(s) (e.g., 152, 252, 352, 452) and / or second portion(s) (e.g., 154, 254, 354, 454), and / or interlayers (e.g., 160, 260, 360, 460), may provide one or more benefits over conventional electrochemical cells and / or conventional electrochemical cells assemblies having conventional separators, for example, including: reducing inactive space, increasing the ratio of active to inactive space in the cell or assembly, inhibiting (e.g., minimizing, reducing, eliminating) dendrite growth or formation, increasing safety of the cell, increasing ionic conductivity between electrodes, improving rate capabilities (e.g., faster charge rates) of batteries, improving flexibility of cell or battery design, reducing material consumption, and / or improving overall performance of the cell or battery.|0.106| FIG. 5 is a block diagram of a method 500 of forming an electrochemical cell including a plurality of separators and an interlayer, according to an embodiment. The method 500 includes disposing an interlayer on a first separator, at 502, and disposing a second separator on the interlayer opposite the first separator to form a separator assembly, at 504. The method 500 further includes modifying at least one of the first separator or the second separator to form at least one first portion having a first property and a second portion having a second property different from the first property, at 506. The method further includes disposing an anode disposed on an anode current collector on the first separator, at 508, and disposing a cathode disposed on a cathode current collector on the second separator, at 510.

[0107] In some embodiments, the electrochemical cell as formed by method 500, and all components thereof, may be similar to, or substantially the same as, electrochemical cell(s) 100, 200, and all components thereof, as previously described with respect FIGS. 1 or 2,39328896850Agent’s File Ref. 24MT-207 / 01WO 314552-3086respectively. In some embodiments, the electrochemical cell formed by method 500, and all components thereof, may be incorporated into the electrochemical cell assembly 400 as previously described with respect to FIG. 4. Furthermore, in some embodiments, the separator assembly of method 500 may be similar to, or substantially the same as, any of separator assemblies 255, 355, 455, as previously described with respect to FIGS. 2, 3, or 4, respectively. For example, in some embodiments, the anode, the anode current collector, the cathode, the cathode current collector, the first separator and the second separator (collectively referred to as “separator(s)”), the first portion, the second portion, and / or the interlayer included in method 500 may be similar to, or substantially the same as, the anode(s) 110, 210, 410, the anode current collector(s) 120, 220, 420, the cathode(s) 130, 230, 430, the cathode current collector(s) 140, 240, 440, the separator(s) 150, 250, 350, 450 the first portion(s) 152, 252, 352, 452, the second portion(s) 154, 254, 354, 454, and / or the interlayer 160, 260, 360, 460, respectively, as previously described with respect to FIGS. 1, 2, 3, and 4. Therefore, certain features of the electrochemical cell, the anode, the anode current collector, the cathode, the cathode current collector, the separator assembly, the separator(s), the first portion, the second portion, and / or the interlayer of method 500 are not described in further detail herein.

[0108] While certain features of the method 500 may be described with respect to the electrochemical cell 100 of FIG. 1, the method 500 is equally applicable to any electrochemical cell (e.g., cell 100, 200) and / or electrochemical cell assembly (e.g., assembly 400), and may include any of the anodes (e.g., anodellO, 210, 410), anode current collectors (e.g., current collector 120, 220, 420), cathodes (e.g., cathode 130, 230, 430), cathode current collectors (e.g., cathode current collector 140, 240, 440), separators (e.g., separator 150, 250, 350, 450), interlayers (e.g., interlayer 160, 260, 360, 460), and / or separator assemblies (e.g., separator assembly 255, 355, 455), as described herein. All such variations should be considered to be within the scope of this disclosure.|0109| At 502, the disposing of the interlayer (e.g., interlayer 160) on the first separator (e.g., first separator 150a) may be accomplished by any suitable method or apparatus. For example, in some embodiments the interlayer (e.g., interlayer 160) may be disposed on the first separator (e.g., first separator 150a) via a dispenser, a nozzle, and / or a coating device, or a sputtering device. For example, in some embodiments, the interlayer (e.g., interlayer 160) may be dispensed on the first separator (e.g., first separator 150a). In some embodiments, the interlayer (e.g., interlayer 160) may be incorporated on the first separator (e.g., first separator 150a). In some embodiments, the interlayer (e.g., interlayer 160) may be coated on the first40328896850Agent’s File Ref. 24MT-207 / 01WO 314552-3086separator (e.g., first separator 150a). In some embodiments, the interlayer (e.g., interlayer 160) may be sputtered on the first separator (e.g., first separator 150a), for example, as one or more layers. In some embodiments, a slurry of conductive material may be casted on the first separator (e.g., first separator 150a) to form, or dispose, the interlayer (e.g., interlayer 160) thereon.

[0110] In some embodiments, the interlayer (e.g., interlayer 160) may be disposed on the first separator (e.g., first separator 150a) via wet lamination. For example, the second separator (e.g., second separator 150b) can be laminated on the first separator while the disposed conductive material is wet (before drying). In some embodiments, the assembled separator can then be subject to a drying process (e.g., air drying, vacuum drying, heat drying, or any suitable combination thereof) to form the separator assembly. In some embodiments, the interlayer (e.g., interlayer 160) may be disposed on the first separator (e.g., first separator 150a) via dry lamination. For example, the second separator can be laminated on the first separator to form the separator assembly while the disposed conductive material is dry or being dried. In some embodiments, the interlayer (e.g., interlayer 160) may be disposed on the first separator (e.g., first separator 150a), for example, laminated thereon with a precut tab or preformed tab thereon. For example, the first separator (e.g., first separator 150a) and / or second separator (e.g., second separator 150b): can be precut (e.g., laser cut, stamp cut, die cut, etc.) to include a tabbing area. The separators can then go through a lamination process, for example, wet or dry lamination. In some embodiments, the separator assembly may be assembled via a multilayer coating process. For example, the interlayer (e.g., a conductive layer) can initially be disposed (e.g., coated) on the first separator or the second separator via inkjet printing, spraying, dispensing, casting, any other suitable method or combination thereof. The other one of the first or second separator can then be applied by disposing a layer of insulating materials thereon via inkjet printing, spraying, dispensing, casting, any other suitable method or combination thereof. |01ll[ At 504, the disposing of the second separator (e.g., second separator 150b) on the interlayer (e.g., interlayer 160) opposite the first separator (e.g., first separator 150a) may be accomplished by any suitable method. For example, in some embodiments, the second separator (e.g., second separator 150b) may be incorporated on a surface of the interlayer (e.g., interlayer 160). In some embodiments, the second separator (e.g., second separator 150b) may be applied to a surface of the interlayer (e.g., interlayer 160). In some embodiments, the second separator (e.g., second separator 150b) may be laminated on the interlayer (e.g., interlayer 160).41328896850Agent’s File Ref. 24MT-207 / 01WO 314552-3086

[0112] At 506, the modifying the separator(s) (e.g., separator 150) may be accomplished via any suitable method or apparatus. For example, in some embodiments, the separator(s) (e.g., separator 150) may be modified by incorporating SSE to form the first portion(s) (e.g., first portion 152). In some embodiments, the modifying may include disposing the SSE on at least a portion of the separator(s) 150 to form the first portion(s) (e.g., first portion 152). In some embodiments, the modifying may include embedding the SSE in one or more pores of the separator(s) (e.g., separator 150) to form the first portion(s) (e.g., first portion 152). In some embodiments, the modifying may include casting a slurry, for example, of SSE, on at least a portion of the separator(s) (e.g., separator 150) to form the first portion (e.g., first portion 152). In some embodiments, the modifying may include infusing at least a portion of the separator(s) (e.g., separator 150) with the SSE to form the first portion(s) (e.g., first portion 152). In some embodiments, the modifying may include masking at least a portion of the separator(s) (e.g., separator 150), for example, to prevent modification of at least a portion of the separator(s) (e.g., separator 150) to form the second portion(s) (e.g., second portion 154). In some embodiments, the separator assembly (e.g., assembly including the first separator 150a, the second separator 150b, and the interlayer 160 disposed therebetween) may be used as a standalone separator assembly that may be incorporated in any suitable electrochemical cell (e.g., the electrochemical cell 100).

[0113] At 508, the disposing the anode (e.g., anode 110) disposed on the anode current collector (e.g., anode current collector 120) on the first separator (e.g., first separator 150a) may be accomplished via any suitable method or apparatus. Likewise, at 510, the disposing the cathode (e.g., cathode 130) disposed on the cathode current collector (e.g., cathode current collector 140) on the second separator (e.g., second separator 150b) may be accomplished via any suitable method or apparatus. For example, in some embodiments, in some embodiments, the anode (e.g., anode 110) or the cathode (e.g., cathode 130) may be incorporated on the separator(s) (e.g., separator 150), for example, on a surface of the separator(s) (e.g., separator 150).

[0114] Various concepts may be embodied as one or more methods, of which at least one example has been provided. The acts performed as part of the method may be ordered in any suitable way. Accordingly, embodiments may be constructed in which acts are performed in an order different than illustrated, which may include performing some acts simultaneously, even though shown as sequential acts in illustrative embodiments. Put differently, it is to be understood that such features may not necessarily be limited to a particular order of execution,42328896850Agent’s File Ref. 24MT-207 / 01WO 314552-3086but rather, any number of threads, processes, services, servers, and / or the like that may execute serially, asynchronously, concurrently, in parallel, simultaneously, synchronously, and / or the like in a manner consistent with the disclosure. As such, some of these features may be mutually contradictory, in that they cannot be simultaneously present in a single embodiment. Similarly, some features are applicable to one aspect of the innovations, and inapplicable to others.

[0115] In addition, the disclosure may include other innovations not presently described. Applicant reserves all rights in such innovations, including the right to embodiment such innovations, file additional applications, continuations, continuations-in-part, divisionals, and / or the like thereof. As such, it should be understood that advantages, embodiments, examples, functional, features, logical, operational, organizational, structural, topological, and / or other aspects of the disclosure are not to be considered limitations on the disclosure as defined by the embodiments or limitations on equivalents to the embodiments. Depending on the particular desires and / or characteristics of an individual and / or enterprise user, database configuration and / or relational model, data type, data transmission and / or network framework, syntax structure, and / or the like, various embodiments of the technology disclosed herein may be implemented in a manner that enables a great deal of flexibility and customization as described herein.10H6I All definitions, as defined and used herein, should be understood to control over dictionary definitions, definitions in documents incorporated by reference, and / or ordinary meanings of the defined terms.10117] As used herein, in particular embodiments, the terms “about” or “approximately” when preceding a numerical value indicates the value plus or minus a range of 10%. Where a range of values is provided, it is understood that each intervening value, to the tenth of the unit of the lower limit unless the context clearly dictates otherwise, between the upper and lower limit of that range and any other stated or intervening value in that stated range is encompassed within the disclosure. That the upper and lower limits of these smaller ranges can independently be included in the smaller ranges is also encompassed within the disclosure, subject to any specifically excluded limit in the stated range. Where the stated range includes one or both of the limits, ranges excluding either or both of those included limits are also included in the disclosure.43328896850Agent’s File Ref. 24MT-207 / 01WO 314552-3086

[0118] The phrase “and / or,” as used herein in the specification and in the embodiments, should be understood to mean “either or both” of the elements so conjoined, i.e., elements that are conjunctively present in some cases and disjunctively present in other cases. Multiple elements listed with “and / or” should be construed in the same fashion, i.e., “one or more” of the elements so conjoined. Other elements may optionally be present other than the elements specifically identified by the “and / or” clause, whether related or unrelated to those elements specifically identified. Thus, as a non-limiting example, a reference to “A and / or B”, when used in conjunction with open-ended language such as “comprising” can refer, in one embodiment, to A only (optionally including elements other than B); in another embodiment, to B only (optionally including elements other than A); in yet another embodiment, to both A and B (optionally including other elements); etc.

[0119] As used herein in the specification and in the embodiments, “or” should be understood to have the same meaning as “and / or” as defined above. For example, when separating items in a list, “or” or “and / or” shall be interpreted as being inclusive, i.e., the inclusion of at least one, but also including more than one, of a number or list of elements, and, optionally, additional unlisted items. Only terms clearly indicated to the contrary, such as “only one of’ or “exactly one of,” or, when used in the embodiments, “consisting of,” will refer to the inclusion of exactly one element of a number or list of elements. In general, the term “or” as used herein shall only be interpreted as indicating exclusive alternatives (i.e., “one or the other but not both”) when preceded by terms of exclusivity, such as “either,” “one of,” “only one of,” or “exactly one of.” “Consisting essentially of,” when used in the embodiments, shall have its ordinary meaning as used in the field of patent law.

[0120] As used herein in the specification and in the embodiments, the phrase “at least one,” in reference to a list of one or more elements, should be understood to mean at least one element selected from any one or more of the elements in the list of elements, but not necessarily including at least one of each and every element specifically listed within the list of elements and not excluding any combinations of elements in the list of elements. This definition also allows that elements may optionally be present other than the elements specifically identified within the list of elements to which the phrase “at least one” refers, whether related or unrelated to those elements specifically identified. Thus, as a non-limiting example, “at least one of A and B” (or, equivalently, “at least one of A or B,” or, equivalently “at least one of A and / or B”) can refer, in one embodiment, to at least one, optionally including more than one, A, with no B present (and optionally including elements other than B); in44328896850Agent’s File Ref. 24MT-207 / 01WO 314552-3086another embodiment, to at least one, optionally including more than one, B, with no A present (and optionally including elements other than A); in yet another embodiment, to at least one, optionally including more than one, A, and at least one, optionally including more than one, B (and optionally including other elements); etc.[01211 In the embodiments, as well as in the specification above, all transitional phrases such as “comprising,” “including,” “carrying,” “having,” “containing,” “involving,” “holding,” “composed of,” and the like are to be understood to be open-ended, i.e., to mean including but not limited to. Only the transitional phrases “consisting of’ and “consisting essentially of’ shall be closed or semi-closed transitional phrases, respectively, as set forth in the United States Patent Office Manual of Patent Examining Procedures, Section 2111.03.

[0122] While specific embodiments of the present disclosure have been outlined above, many alternatives, modifications, and variations will be apparent to those skilled in the art. Accordingly, the embodiments set forth herein are intended to be illustrative, not limiting. Various changes may be made without departing from the spirit and scope of the disclosure. Where methods and steps described above indicate certain events occurring in a certain order, those of ordinary skill in the art having the benefit of this disclosure would recognize that the ordering of certain steps may be modified and such modification are in accordance with the variations of the invention. Additionally, certain of the steps may be performed concurrently in a parallel process when possible, as well as performed sequentially as described above. The embodiments have been particularly shown and described, but it will be understood that various changes in form and details may be made.45328896850

Claims

1. Agent’s File Ref. 24MT-207 / 01WO 314552-3086CLAIMS1. An electrochemical cell, comprising:a first electrode disposed on a first current collector;a second electrode disposed on a second current collector;a first separator disposed on the first electrode;a second separator disposed on the second electrode; andan interlayer disposed between the first electrode and the second electrode, wherein the first separator includes a first portion having a first property, and a second portion having a second property different than the first property such that the second portion has higher bendability about a bend axis relative to the first portion.

2. The electrochemical cell of claim 1, wherein the second separator also includes a first portion having a first property, and a second portion having a second property different than the first property such that the second portion has higher bendability about a bend axis relative to the first portion.

3. The electrochemical cell of claim 2, wherein the first portion and the second portion of the second separator are aligned with the first portion and the second portion of the first separator, respectively.

4. The electrochemical cell of claim 1, wherein the second portion is bent about the bend axis, and the first portion is substantially planar.

5. The electrochemical cell of claim 1, wherein the first portion includes a solid-state electrolyte.

6. The electrochemical cell of claim 5, wherein the solid-state electrolyte includes at least one of a sulfide solid-state electrolyte, an oxide-based solid electrolyte material including a garnet structure, a perovskite structure, a phosphate-based Lithium Super Ionic Conductor (LISICON) structure, a sodium ion conductor, beta / beta AI2O3, sodium super ionic conductor NASICON (Nai+xZr2SixP3-xOi2, where 0 < x < 3 ), sodium sulfide Na3PS4, Na3AsS4, Na3SbS4, Na4SiS4, Na4GeS4, Na4SnS4, NanSi2PSi2, NanSmSbSn, closo-type, Na(Cb910)CBuHi2), NaCBnHn, NaCB Hio, Lao.5lLio.34TiO2.94, Lii.3Alo.3Tii.7(P04)3, Lii.4Alo.4Tii.6(P04)3,46328896850Agent’s File Ref. 24MT-207 / 01WO 314552-3086LivLasZnOn, Li6.66La3Zn.6Tao.40i2.9 (LLZO), 50Li4Si04.50Li3B03, Li2.9PO3.3N0.46 (lithium phosphorousoxynitride, LiPON), Li3.6Sio.6Po.4O4, Li3BN2, LisBOs — Li2SO4, LisBOs — Li2SO4 — Li2CO3 (LIBSCO, pseudoternary system), a thio-LISICON structure, a glassy structure, a glass-ceramic structure, Lii.o7Alo.69Tii.46(P04)3, Lii.5Alo.5Gei.5(P04)3, LiioGeP2Si2 (LGPS), 3OLi2S.26B2S3.44Li!, 63Li2S.36SiS2.1Li3PO4, 57Li2S.38SiS2.5Li4SiO4, 70Li2S.30P2S5, 50Li2S.50GeS2, LivPsSn, Li3.25P0.95S4, and Li9.54Sii.74Pi.44Su.7Clo.3, and / or lithium argyrodite LiePSsX (X= Cl, Br) and / or halide electrolytes s Lis-xMi-xXe (M = Y, Er, In, Yb, Ho, X= Cl, Br, I, For closo-type complex hydride solid electrolyte including at least one of LiBHi — Lil, LiBH4 — LiNH2. LiBHi — P2S5, Li(CBxHx+i) — Lil, bis(trifluoromethane)sulfonamide (TFSI), bis(pentalluoroethanesulfonyl)imide (BETI), bis(fluorosulfonyl)imide, lithium borate oxalato phosphine oxide (LiBOP), lithium bis(fluorosulfonyl)imide, amide-borohydride, LiBF4, LiPFe, LIF, a sodium salt, a potassium salt, a magnesium salt, a zinc salt, a cesium salt, a indium salt, a tin salt, an antimony salt, a silicon salt, a nickel salt, or a cobalt salt.

7. The electrochemical cell of claim 5, wherein the second portion does not include the solid-state electrolyte.

8. The electrochemical cell of claim 5, wherein the first portion includes a plurality of pores, the solid-state electrolyte disposed in at least a portion of the plurality of pores.

9. The electrochemical cell of claim 1 , wherein the first property is a first flexural modulus, and the second property is a second flexural modulus, the second flexural modulus less than the first flexural modulus.

10. The electrochemical cell of claim 1, wherein the first property is a first elastic modulus, and the second property is a second elastic modulus, the second elastic modulus less than the first elastic modulus.

11. The electrochemical cell of claim 1, wherein the interlayer includes a conductive material.

12. The electrochemical cell of claim 11, wherein the conductive material includes at least one of a carbonaceous material, aluminum, LFP, LCO, or NMC.47328896850Agent’s File Ref. 24MT-207 / 01WO 314552-308613. The electrochemical cell of claim 11, wherein the conductive material includes a conductive coating disposed on the interlayer.

14. The electrochemical cell of claim 1, further comprising:a tab extending from the interlayer, the tab extending beyond at least one of the first separator or the second separator.

15. The electrochemical cell of claim 1, further comprising:a controller electrically coupled to the interlayer and at least one of the first electrode or the second electrode, the controller configured to selectively cause electrical energy to be communicated from at least one of the first electrode or the second electrode to the interlayer to maintain a voltage between the interlayer and at least one of the first electrode or the second electrode above a threshold value.

16. An electrochemical cell, comprising:an anode disposed on an anode current collector;a cathode disposed on a cathode current collector; anda separator assembly disposed between the anode and the cathode, the separator assembly including a first portion and a second portion, the first portion having a first flexural modulus, the second portion having a second flexural modulus, the first flexural modulus greater than the second flexural modulus.

17. The electrochemical cell of claim 16, wherein the separator assembly includes a first separator, a second separator, and an interlayer disposed between the first separator and the second separator.

18. The electrochemical cell of claim 17, wherein at least one of the first separator or the second separator includes the first portion and the second portion.

19. The electrochemical cell of claim 18, wherein each of the first separator and the second separator include a corresponding first portion and second portion, the corresponding first portion having the first flexural modulus, and the corresponding second portion having the second flexural modulus.48328896850Agent’s File Ref. 24MT-207 / 01WO 314552-308620. The electrochemical cell of claim 17, wherein the first separator includes the first portion and the second portion, and the second separator includes:a third portion having a third flexural modulus, anda fourth portion having a fourth flexural modulus, the third flexural modulus greater than the fourth flexural modulus.

21. The electrochemical cell of claim 20, wherein the third flexural modulus is substantially equal to the first flexural modulus, and the fourth flexural modulus is substantially equal to the second flexural modulus.

22. The electrochemical cell of claim 17, wherein the interlayer includes a conductive material.

23. The electrochemical cell of claim 22, wherein the conductive material includes at least one of a carbonaceous material, aluminum, LFP, LCO, or NMC.49328896850

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