Electrode stacking assembly

Abstract

An electrode stacking assembly (300) comprises a holding structure (100) and a partially or wholly fabricated electrochemical cell, the holding structure comprising a holding structure alignment member (110) that is configured to engage with an electrode alignment member (210) provided by an electrode of the partially or wholly fabricated electrochemical cell.

Description

[0001] ELECTRODE STACKING ASSEMBLY

[0002] Field of the invention

[0003] The present disclosure relates generally to the stacking of electrodes and particular, although not exclusive, utility in providing stacking of electrodes for solid state batteries.

[0004] Background to the invention

[0005] A cell includes an anode and a cathode. A battery includes several cells. A battery is formed through the stacking of the electrodes.

[0006] Lithium-ion batteries are formed from successive stacks of a cathode, an electrical separator, an anode, and an electrical separator. Existing stacking methods include z-folding and winding. Z-folding includes providing alternate anode and cathode electrodes between a zig-zagged electrical separator. Electrode winding includes alternate layering of anodes, electrical separators, cathodes and electrical separators, followed by rolling to form either a cylindrically or a prismatically wound cell. The electrode stacking assemblies are then placed in a protective pouch or housing of an electrical separator.

[0007] Misalignment of electrodes may cause short circuiting.

[0008] Summary of the invention

[0009] In a first aspect of the present disclosure, there is provided a partially or wholly fabricated electrochemical cell comprising a first electrode and an electrically insulating separator layer; the first electrode comprising an electrode body, a first current collector tab and a second current collector tab, the electrode body comprising an electrode active material layer, and wherein the first current collector tab and the second current collector tab protrude from the electrode body and the first current collector tab and the second current collector tab are located at opposing ends of the electrode body.In this way, the current may be collected from either side of the electrode and thus the distance travelled by the current may be reduced and the efficiency of the electrode can be increased.

[0010] Preferably, the electrode body is substantially rectangular, and the first current collector tab is located substantially diagonally opposite the second current collector tab.

[0011] The electrode may be an anode or a cathode. In some embodiments, the electrodes are suitable for use in solid state batteries. In some such embodiments, the electrically insulating separator layer is attached to the electrode. In this way, the assembly of the battery is simpler as the number of individual components required to be stacked is reduced. For the avoidance of doubt, the electrically insulating separator layer covers only the electrode body and not the current collector tabs.

[0012] The electrode body is typically substantially rectangular, with the current collector tabs located on the short sides of the electrode body.

[0013] In some embodiments, the first current collector tab and the second current collector tab are connected by a current collector layer extending across the electrode body, and wherein the current collector layer and the electrically insulating separator layer sandwich the electrode active material layer.

[0014] In some embodiments, the partially or wholly fabricated cell comprises a second electrode, the second electrode comprising a substantially rectangular electrode body, and a first current collector tab protruding from the electrode body, and the electrode body comprises an electrode active material layer.In some embodiments, the second electrode comprises a second current collector tab protruding from the electrode body, wherein the first current collector tab of the second electrode and the second current collector tab of the second electrode are located at opposing ends of the electrode body. In this way, the maximum distance required to be travelled by the current is reduced, and therefore the efficiency of the second electrode can be increased.

[0015] In some embodiments, the first current collector tab of the second electrode is located substantially diagonally opposite the second current collector tab of the second electrode. In a second aspect of the disclosure, there is provided a partially or wholly fabricated electrochemical cell comprising a first electrode and an electrically insulating separator layer, the first electrode comprising an electrode body, a first current collector tab, and a first electrode alignment member; the electrode body comprising an electrode active material layer, wherein the first electrode alignment member is configured to engage with a holding structure.

[0016] The first electrode alignment member is configured to cooperate with an alignment member of a holding structure for an electrode stacking assembly. In this way, there is provided a partially or wholly fabricated electrochemical cell that is easier for a user to place within an electrode stacking assembly in the desired position. The partially or wholly fabricated electrochemical cell can be placed within the holding structure to provide a stacking assembly with improved retention of the electrode positioning, and therefore improved stability.

[0017] For the avoidance of doubt, the term ‘electrically insulating separator layer’ refers to the component of an electrochemical cell that has the function of separating an anode and a cathode. As such, the electrically insulating separator layer inhibits the movement of electrons and is free from electroactive material.The alignment features of the present invention enables electrode stacking assemblies to be formed without the need for z-folding or winding of electrical separators to maintain the alignment of the electrodes. In this way, the range materials that can be used for the electrical separator layer is increased as the electrical separator does not need to be flexible. The first electrode alignment member of the present invention provides improved location, alignment and retention of the partially or wholly fabricated cell within a holding structure to reduce the chances of misalignment.

[0018] Preferably, the first electrode alignment member comprises a hole, a groove, a depression, or a slot. In this way, the hole, groove, depression or slot of the electrode may accommodate a protrusion, hook, dowel or pin of the holding structure alignment member. More preferably, the first electrode alignment member comprises a pair of holes, grooves, depressions or slots. In this way, when in use stacked in a holding structure with a corresponding alignment member, the freedom of movement of the wholly or partially fabricated electrochemical cell is further reduced.

[0019] Preferably, the first electrode alignment member is provided by the first current collector tab. In this way, the route of the current is not interrupted by the alignment member.

[0020] Preferably, the first electrode comprises a second current collector tab. Preferably, the first current collector tab and the second current collector tab are located at opposite ends of the electrode body. In this way, the current may be collected from either side of the electrode and thus the distance travelled by the current may be reduced and the efficiency of the electrode can be increased.

[0021] Preferably, the first electrode comprises a first electrode alignment member provided by the first current collector tab, and a second electrode alignment member provided by the secondcurrent collector tab, wherein the second electrode alignment member is configured to engage with the holding structure. In this way, the first electrode is configured to engage with a holding structure at both the first and second electrode alignment member, therefore there is provided improved alignment and retention of the first electrode when stacked within a holding structure. More preferably, the first current collector tab is located substantially opposite the second current collector tab. In this way, the first electrode alignment member is located substantially opposite the second electrode alignment member, and therefore the freedom of movement of the first electrode within a holding structure is further reduced. In this way, the alignment and retention of the first electrode within a stacking assembly comprising a holding structure is further improved. Most preferably, the electrode body is substantially rectangular, and the first current collector tab is located substantially diagonally opposite the second current collector tab. In this way, the first and second alignment members are substantially diagonally opposite each other and therefore provide improved alignment of the electrode with reduced torsion when stacked within a holding structure to form an electrode stacking assembly.

[0022] In some embodiments, the first current collector tab and the second current collector tab are connected by a current collector layer extending across the electrode body, and wherein the current collector layer and the electrically insulating separator layer sandwich the electrode active material layer.

[0023] In some embodiments, the partially or wholly fabricated cell comprises a second electrode the second electrode comprising a substantially rectangular electrode body, and a first current collector tab protruding from the electrode body, and the electrode body comprises an electrode active material layer.

[0024] Preferably, the second electrode comprises a first alignment member, and the first alignment member of the second electrode is configured to engage with a holding structure. In thisway, there is provided a partially or wholly fabricated cell that is easier for a user to place within an electrode stacking assembly in the desired position. Additionally, the partially or wholly fabricated electrochemical cell can be placed with the holding structure to provide a stacking assembly with improved retention of the desired electrode positioning, and therefore improved stability. More preferably, the second electrode further comprises a second alignment member, and the second alignment member of the second electrode is configured to engage with a holding structure. In this way, the partially or wholly fabricated cell provides further improved alignment, retention and stability within a corresponding holding structure.

[0025] The electrodes may be an anode or a cathode. In some embodiments, the electrodes are suitable for use in solid state batteries. In some embodiments, the electrically insulating separator layer is ionically conductive. In this way, the electrically insulating separator layer forms the electrolyte layer of an electrochemical cell. In some such embodiments, the electrochemical cell is a solid state cell.

[0026] In alternative embodiments, the electrically insulating separator layer is ionically non-conductive. In this way, an additional electrolyte, such as a liquid electrolyte, is required to form a cell. In such embodiments, the electrically insulating separator layer is porous.

[0027] In some embodiments, the electrically insulating separator layer is attached to the first electrode. In this way, the total number of components that need to be stacked is reduced. For the avoidance of doubt, the electrically insulating separator layer covers only the electrode body and not the current collector tabs.

[0028] The electrode body is typically substantially rectangular, with the current collector tabs located on the short sides of the electrode body.Where the wholly or partially fabricated electrochemical cell of the first or second aspect of the present invention comprises a first electrode and a second electrode, one of the first and second electrodes is an anode and the other of the first and second electrodes is a cathode. Typically, the current collector tabs of the first electrode are displaced from the current collector tabs of the second electrode in a direction in the plane of the electrode bodies. In other words, the current collector tabs of a cathode are not typically superimposed on the current collector tabs of an anode.

[0029] In a third aspect of the present disclosure, there is provided an electrode stacking assembly, comprising a holding structure and a partially or wholly fabricated electrochemical cell of the second aspect of the disclosure, the holding structure comprising and a first holding structure alignment member; and the first holding structure alignment member is configured to engage with the first electrode alignment member of the first electrode of the partially or wholly fabricated electrochemical cell of the second aspect of the disclosure.

[0030] In this way, there is provided an electrode stacking assembly with improved positioning, alignment and retention of electrodes. The corresponding first holding structure alignment member and first electrode alignment member can guide the positioning of the electrode stacking to provide improved alignment of electrodes. The engagement of the first electrode alignment member by the first holding structure alignment member can provide improved stability and retention of the partially or wholly fabricated electrochemical cell within the holding structure. The electrode stacking assembly can therefore be handled and transported with increased stability and reduced risk of misalignment.

[0031] In some embodiments, the partially or wholly fabricated cell comprises a second electrode, the second electrode comprising an electrode body and a first current collector tab, and the electrode body comprises an electrode active material layer. Preferably, the holding structure comprises a second holding structure alignment member, the second electrodecomprises a first electrode alignment member, the first holding structure alignment member cooperating with the first electrode alignment member of the first electrode and the second holding structure alignment member cooperating with the first electrode alignment member of the second electrode. In this way, both the first and second electrodes of the electrode stacking assembly are provided with improved alignment, retention and stability through the engagement with the holding structure.

[0032] In some embodiments, the holding structure comprises a third holding structure alignment member and a fourth holding structure alignment member. In this way, the holding structure may engage with a partially or wholly fabricated electrochemical cell comprising a first electrode and a second electrode, wherein each of the first electrode and the second electrode comprise a first electrode alignment member and a second electrode alignment member.

[0033] In some embodiments, the electrode stacking assembly comprises two partially or wholly fabricated electrochemical cells, with the first electrodes superimposed one on another and the second electrodes superimposed on one another. For the avoidance of doubt, the first electrodes are stacked alternately with the second electrode. In other words, there is provided an electrode stacking assembly with cathode current collector tabs positioned substantially in line with other cathode current collector tabs, and anode current collector tabs substantially in line with other anode current collector tabs. In this way, the electrode stacking assembly can be welded to join the superimposed anode current collector tabs to form a combined anode current collector tab, and the cathode current collector tabs can be welded to join the cathode current collector tabs to form a combined cathode current collector tab. In this way, one electrode contact can be used to connect the current collector tabs of many electrodes.In some embodiments, the electrodes are solid state electrodes. In some such embodiments, for one of the electrode types within the electrode stacking assembly, i.e. the anodes or cathodes, the electrically insulating separator layer is attached to the electrode body. In this way, the assembly of the battery is simpler as the number of individual components required to be stacked is reduced.

[0034] Preferably, the first holding structure alignment member comprises a protrusion, a hook, a dowel or a pin. In this way, the dowel or pin of the holding structure may fit into a corresponding hole or slot in the electrode. Preferably, the second, third and / or fourth holding structure alignment members comprise a protrusion, a hook, a dowel or a pin. In this way, the dowel or pin of the holding structure may fit into a corresponding hole or slot in the electrode. In this way, improved engagement of the partially or wholly fabricated cell with the holding structure is provided.

[0035] The holding structure may be any shape suitable for housing partially or wholly fabricated electrochemical cells. For example, the holding structure may be a plate, a tray, or a frame. For the avoidance of doubt, a plate is defined as a substantially flat structure extending from one end of an electrode to another. A plate may cover a single side of an electrode stack. A tray is defined as an open-ended structure that covers at least a first and second side of an electrode stack, preferably a first, second and third side of an electrode stack, more preferably a tray comprises a base and four substantially perpendicular sides. A frame is defined as a structure which substantially surrounds the four outer sides of an electrode stack but does not extend across the upper or lower electrode bodies of the electrode stack. For the avoidance of doubt, the four outer sides of an electrode stack are defined as the sides that comprise the edges of the electrodes. In other words, a frame is a tray without a base.In some embodiments, the structure is substantially C-shaped, and surrounds three of the four outer sides of an electrode stack. In other words, the structure is a frame with one less side.

[0036] Preferably, the holding structure is a frame. In this way, when electrodes are added to the holding structure to form a stacking assembly, the holding structure does not substantially increase the height of a stacking assembly. Preferably, the frame comprises a platform substantially perpendicular to the sides of the frame, extending inwardly, to provide a base for a holding structure alignment member. Preferably, the frame comprises said platform for each holding structure alignment member. In this way, the holding structure alignment members of the frame, such as dowels, may be substantially parallel to the sides of the frame.

[0037] In alternative embodiments, the holding structure is a plate. In this way, when electrodes are added to the structure to form a stacking assembly, the holding structure does not substantially increase the width of a stacking assembly.

[0038] Preferably, the holding structure comprises plastic. In this way, the holding structure allows for the heating and reshaping of one or more portions of the assembly to secure the location of the electrodes within the stacking assembly. In this way, once reshaped, the stacking assembly can be transported with a reduced risk of misalignment of electrodes.

[0039] Preferably, the holding structure alignment member comprises plastic. In this way, the holding structure alignment member may be heated and reshaped to secure electrodes in place within the stacking assembly. More preferably, the holding structure alignment member is a dowel and comprises plastic. In this way, once the electrodes are fitted within the holding structure to form a stacking assembly, the stacking assembly may be heated andreshaped, causing the dowels to form rivets and secure the electrodes in position within the stacking assembly.

[0040] In some embodiments, the holding structure consists of plastic. In this way, the entire holding structure may be heated and reshaped to secure that position of the electrodes within an electrode stacking assembly. Additionally, the use of plastic rather than metal to form the structure is advantageous. Plastic is typically lighter than metal and therefore may allow for the formation of lighter stacking assemblies. Plastic is also typically insulating and therefore may reduce the risk of short circuiting relative to metal structures.

[0041] Preferably, the holding structure is integrally formed. Alternatively, the holding structure may be formed from several components.

[0042] Preferably, the holding structure comprises a plurality of apertures. In this way, a liquid electrolyte can be added through the apertures, providing easier soaking of an electrode stacking assembly with a liquid electrolyte layer to form a cell.

[0043] Preferably, the holding structure comprises at least two holding structure alignment members. Preferably, the holding structure comprises a first holding structure alignment member and a second holding structure alignment member, the first holding structure alignment member cooperating with the electrode alignment member of the anode and the second holding structure alignment member cooperating with the electrode alignment member of the cathode. The electrode alignment members may then be located in the current collector tabs of the electrode, without risking short circuit through contact of the anode and cathode current collector tabs, as the anode and cathode alignment members are positioned over different alignment members of the structure.Preferably, the holding structure has a substantially rectangular cross section. For example, where the holding structure is a frame, the sides of the frame form a rectangle. Preferably, the holding structure comprises four holding alignment members. More preferably, each of the four holding structure alignment members is located substantially in the corners of the substantially rectangular holding structure. In this way, the structure accommodates electrodes with substantially diagonal alignment members and provides improved alignment of electrodes with reduced torsion.

[0044] Preferably, the anodes and cathodes are stacked alternately in the structure in a mirrored configuration, with each of the cathodes in the same orientation as each other, and each of the anodes in the same orientation as each other. In this way, the anode current collector tabs overlay each other, and the cathode current collector tabs overlay each other.

[0045] In some embodiments, the anode and cathode may have different shaped alignment members, each cooperating with a certain alignment member of the holding structure. For example, the anode may have square holed alignment members, and the cathode may have round holed alignment members. The holding structure may then have cylindrical dowels as alignment members for the cathodes and rectangular dowels as alignments members for the anodes. In this way, the risk of electrodes being stacked in the wrong positions leading to a short circuit is further reduced.

[0046] Preferably, the holding structure comprises a barrier element that is located between the anode current collector tab and the cathode current collector tab. In this way, the risk of short circuiting is further reduced.

[0047] Preferably, the electrode stacking assembly comprises an electrode contact in contact with each of the combined current collector tabs. More preferably, the electrode contacts comprise electrode contact alignment members cooperating with the holding structurealignment members. In this way, the electrode contacts can be easily positioned, aligned, and retained within the electrode stacking assembly, in the same way as the electrodes.

[0048] Preferably, the holding structure alignment members are configured to secure the electrodes in position. In this way, the risk of disassembly of the electrode stacking assembly is reduced.

[0049] In a fourth aspect of the invention, there is provided a method of providing an electrode stacking assembly of the third aspect of disclosure, the method comprising stacking a partially or wholly fabricated electrochemical cell of the second aspect of the disclosure onto a holding structure comprising a first holding structure alignment member; and the first holding structure alignment member engages with an electrode alignment member of the partially or wholly fabricated cell to control the position of the electrode within the holding structure.

[0050] Preferably, the method comprises the stacking of at least two partially or wholly fabricated cells of the second aspect of disclosure along a stacking axis direction perpendicular to a plane comprising the rectangular electrode body of the partially or wholly fabricated electrochemical cell, wherein the stacking of the partially or wholly fabricated electrochemical cells provides cathode current collector tabs superimposed in the stacking direction, anode current collector tabs superimposed in the stacking direction, and the cathode current collector tabs are displaced from the anode current collector tabs in a direction parallel to the plane comprising the rectangular electrode body of the partially or wholly fabricated electrochemical cell.

[0051] Preferably, the method further comprises welding of the superimposed cathode current collector tabs together to form a combined cathode current collector tab, and welding of thesuperimposed anode current collector tabs to form a combined anode current collector tab. In this way, one electrode contact can be used to connect the current collector tabs of many anodes, and one electrode contact can be used to connect the current collector tabs of many cathodes.

[0052] The welding of the superimposed current collector tabs may be laser welding or ultrasonic welding. Preferably, the welding is ultrasonic welding. In this way, the method may have lower energy requirements.

[0053] Preferably, the method further comprises fastening the electrode stack within the holding structure. In this way, improved retention of the position of the electrodes within the holding structure is provided and therefore the risk of short circuiting through the misalignment of electrodes is reduced. In some embodiments, the electrode stack is fastened by clipping adjacent holding structure alignment members together. In some embodiments, the electrode stack is fastened by adding a fastener such as a nut to a holding structure alignment member. In these ways, the electrodes are fastened within the stacking assembly as the clip or fastener attached to the holding structure alignment member is larger than electrode alignment member, for example the fastener on the holding structure alignment member is larger than the hole in the electrode which is engaged with the holding structure alignment member. In this way, the electrode cannot be easily removed or misaligned in the electrode stacking assembly.

[0054] Preferably, the method further comprises heating and reshaping of one or more portions of the holding structure. In this way, the one or more portions of the holding structure changes shape, restricts the movement of the electrodes and thus provides improved retention of the electrodes within the holding structure. More preferably, the method comprises fastening the electrode stack within the holding structure by heating and reshaping of the holding structure alignment members. In this way, the alignment member changes shape, restricts themovement of the electrodes and thus provides improved retention of the electrodes within the holding structure. Where the holding structure alignment members are dowels, the heat and reshaping step may cause the dowels to change shape to form rivets, to fasten the electrodes within the electrode stacking assembly. The heating and reshaping of the holding structure alignment members may be carried out by heat staking.

[0055] In certain examples, the heating of the one or more portions of the holding structure may be carried out indirectly through the application of ultrasonic vibration (since this is thought to create friction within the material). This process may be referred to as ultrasonic staking.

[0056] The welding of the structure may be ultrasonic welding or heat welding.

[0057] For the avoidance of doubt, as used herein the term “ultrasonic” refers to frequencies of 20 kHz or more.

[0058] In some embodiments, the method further comprises adding a liquid electrolyte to the electrode stacking assembly to provide a cell. In some such embodiments, the liquid electrolyte may be added through apertures in the sides of the holding structure. In this way, the addition of the liquid electrolyte through the apertures allows for easier soaking of an electrode stacking assembly to form a cell.

[0059] Preferred features are not limited to the aspect of the invention for which they are described. For example, features of the partially or wholly fabricated electrochemical cells of the first and second aspects of the disclosure, or the stacking assembly of the third aspect may be combined with the method of the fourth aspect of the disclosure. For example, features described in relation to a first holding structure alignment member may also be applied to second, third and fourth holding structure alignment members, and features described inrelation to a first electrode alignment member may also be applied to a second electrode alignment member.

[0060] Detailed description

[0061] The invention will now be described by way of example with reference to the following Figures in which:

[0062] Figure 1 shows a schematic of a frame, an example of a holding structure as part of the stacking assembly of the third aspect of the disclosure;

[0063] Figure 2 shows a schematic of a partially fabricated cell of the first and second aspects of the disclosure;

[0064] Figure 3 shows a schematic of an electrode stacking assembly of the third aspect of the disclosure;

[0065] Figure 4 shows an exploded view of the electrode stacking assembly of Figure 3; and

[0066] Figure 5 shows a top view of the electrode stacking assembly of Figure 3.

[0067] The invention is not limited to the specific examples or structures illustrated, a greater number of components than are illustrated in the Figures could be used, for example. The specific examples have particular combinations of features, however, it is envisaged that further combinations and cross-combinations of compatible features between embodiments will be possible. Indeed, isolated features may function independently as an invention from other features and not necessarily require implementation as a complete combination.

[0068] Figure 1 shows a frame 100 configured to house an electrode stack. Frame 100 has a platform extending inwardly from each corner of the frame, with each platform comprising a pair of vertical dowels 110 as an alignment member. The dowels 110 control the positioning of the electrode 200 on to the frame 100 to provide the desired alignment. Frame 100 is integrally formed from plastic.The frame 100 has a plurality of apertures 150. In this way, a liquid electrolyte can be added to an electrode stacking assembly through the apertures 150, providing easier soaking of the electrode stacking assembly with a liquid electrolyte layer to form a cell.

[0069] Figure 2 shows an electrode 200 with an electrode body 205, current collector tabs 220, and holes 210 as the electrode alignment member. The electrode 200 includes two substantially diagonally opposite current collector tabs 220, each with holes 210 as an electrode alignment member. The current collector tabs are on opposing sides of the electrode, reducing the distance required to be travelled by the current.

[0070] The electrodes 200 include two types - anodes and cathodes. One of the types of electrode, includes an electrically insulating separator layer attached to the electrode body 205. In this way, the electrically insulating separator layer helps to prevent short circuits between anodes and cathodes.

[0071] The holes 210 of the electrode 200 fit with the dowels 110 of the frame 100 to control the alignment of the electrode 200 within the frame 100. The substantially diagonally opposite holes 210 allow for alignment of the electrode in the frame with reduced torsion.

[0072] Figure 3 shows an electrode assembly stack 300 formed from the frame 100, two or more electrodes 200, and electrode contacts 330.

[0073] Figure 4 shows an exploded view of electrode stacking assembly 300 formed from the frame 100, two or more electrodes 200, and electrode contacts 330. The electrode contacts 300 also have holes 310 as an alignment member. The holes 310 fit over the dowels 110 of the frame 100 to control the alignment of the electrode contacts 330 in the stacking assembly 300.

[0074] The anodes and cathodes are placed alternately in the frame 100 in a mirrored configuration, with each of the cathodes in the same orientation as each other, and each of the anodes in the same orientation as each other. In this way, the anode current collector tabs overlay each other, and the cathode current collector tabs overlay each other. The electrodes are stacked in the frame along a stacking direction A, perpendicular the rectangular electrode body of the electrodes 200.

[0075] A portion of the electrode stacking assembly 300 is heated and reshaped. In the heating and reshaping step, the portion of the plastic frame, melts or softens, changes shape, sets,and secures the electrodes within the electrode stacking assembly with the desired alignment. The dowels 110 are heated and reshaped to form rivets, to fasten the electrodes within the electrode stacking assembly 300. That is, the dowels 110 are reshaped so that the free ends of the dowels that protrude from the holes of the electrodes have a greater diameter than the sections of the dowels that pass through the holes. The heating and reshaping process is carried out by heat staking.

[0076] The anode current collector tabs are welded together to form combined anode current collector tabs 221. The cathode current collector tabs are welded together to form combined cathode current collector tabs 222.

[0077] Figure 5 shows a top view of the electrode stacking assembly 300.

[0078] The separator 120 of the frame 100 is located between the current collector tabs of the anode and the current collector tabs of the anode to prevent short circuiting.

Claims

CLAIMS1. A partially or wholly fabricated electrochemical cell, comprising a first electrode and an electrically insulating separator layer;the first electrode comprising an electrode body, a first current collector tab, and a first electrode alignment member; the electrode body comprising an electrode active material layer, andwherein the first electrode alignment member is configured to engage with a holding structure.

2. The partially or wholly fabricated electrochemical cell of claim 1 , wherein the first electrode alignment member comprises a hole, a groove, a depression, or a slot.

3. The partially or wholly fabricated electrochemical cell of claim 1 or claim 2, wherein the first electrode alignment member is provided by the first current collector tab.

4. The partially or wholly fabricated electrochemical cell of claim 1 , claim 2 or claim 3, wherein the first electrode comprises a second current collector tab, and the first current collector tab and the second current collector tab are located at opposing ends of the electrode body.

5. The partially or wholly fabricated electrochemical cell of claim 4, wherein the second current collector tab provides a second electrode alignment member, the second electrode alignment member configured to engage with a holding structure.

6. The partially or wholly fabricated electrochemical cell of claim 5, wherein the second electrode alignment member comprises a hole, a groove, a depression, or a slot.

7. The partially or wholly fabricated electrochemical cell of any one of claims 4-6, wherein the first current collector tab and the second current collector tab are connected by a current collector layer extending across the electrode body, andwherein the current collector layer and the electrically insulating separator layer sandwich the electrode active material layer.

8. The partially or wholly fabricated electrochemical cell of any one of claims 4-7, wherein the electrode body is substantially rectangular and the first current collector tab is located substantially diagonally opposite the second current collector tab.

9. The partially or wholly fabricated electrochemical cell of any of claims 1 to 8, wherein the partially or wholly fabricated electrochemical cell comprises a second electrode, the second electrode comprising a substantially rectangular electrode body, and a first current collector tab protruding from the electrode body, and the electrode body comprises an electrode active material layer.

10. The partially or wholly fabricated electrochemical cell of claim 9, wherein the second electrode comprises a first alignment member, and the first alignment member of the second electrode is configured to engage with a holding structure.

11. An electrode stacking assembly comprising a holding structure and a partially or wholly fabricated electrochemical cell of any of claims 1-10, the holding structure comprising a first holding structure alignment member; and the first holding structure alignment member is configured to engage with the first electrode alignment member of the first electrode of the partially or wholly fabricated electrochemical cell of any of claims 1-10.

12. The electrode stacking assembly of claim 11, wherein the partially or wholly fabricated cell comprises a second electrode, the second electrode comprising an electrode body and a first current collector tab, and the electrode body comprises an electrode active material layer.

13. The electrode stacking assembly of claim 12, wherein the holding structure comprises a second holding structure alignment member, the second electrode comprises a first electrode alignment member, the first holding structure alignment member cooperating with the first electrode alignment member of thefirst electrode and the second holding structure alignment member cooperating with the first electrode alignment member of the second electrode.

14. The electrode stacking assembly of claim 12 or claim 13, wherein the holding structure comprises a barrier element, the barrier element configured to keep an anode current collector tab apart from a cathode current collector tab.

15. The electrode stacking assembly of any of claims 11-14, wherein the first holding structure alignment member comprises a protrusion, a hook, a dowel or a pin.

16. The electrode stacking assembly of any of claims 11-15, wherein the holding structure comprises plastic.

17. The electrode stacking assembly of any of claims 11-16, wherein the holding structure is configured to secure the wholly or partially fabricated electrochemical cell in position.

18. The electrode stacking assembly of claim 11 , comprising a partially or wholly fabricated electrochemical cell according to any one of claims 5-8, wherein the holding structure comprises at least two holding structure alignment members, each of the two holding structure alignment members being configured to engage with a respective one of the first and second electrode alignment members of the first electrode.

19. The electrode stacking assembly of claim 18, wherein the two holding structure alignment members each comprise a protrusion, a hook, a dowel or a pin.

20. A method of providing an electrode stacking assembly of any of claims 11-19, the method comprising stacking a partially or wholly fabricated electrochemical cell of any of claims 1-10 onto a holding structure comprising a first holding structure alignment member; and the first holding structure alignment member engages with an electrode alignment member of the wholly or partially fabricated cell to control the position of the electrode within the holding structure.

21. The method of claim 20, wherein the method comprises the stacking of at least two partially or wholly fabricated electrochemical cells of any of claims 1-10 ontothe holding structure along a stacking axis direction perpendicular to a plane comprising the rectangular electrode body of the partially or wholly fabricated electrochemical cell, wherein the stacking of the partially or wholly fabricated electrochemical cells provides cathode current collector tabs superimposed in the stacking direction, anode current collector tabs superimposed in the stacking direction, and the cathode current collector tabs are displaced from the anode current collector tabs in a direction parallel to the plane comprising the rectangular electrode body of the partially or wholly fabricated electrochemical cell.

22. The method of any of claim 21 , wherein the method further comprises welding of the superimposed cathode current collector tabs to form a combined cathode current collector tab, and welding of the superimposed anode current collector tabs to form a combined anode current collector tab.

23. The method of any of claims 20-22, wherein the method further comprises heating or applying vibration to the first holding structure alignment member to change the shape of the first holding structure alignment member to secure the positions of the electrodes within the holding structure.

24. The method of claim 23, wherein the first holding structure alignment member comprises plastic.

25. The method of claim 23 or 24, wherein the first holding structure alignment member comprises a dowel or a pin.

26. The method of any of claims 20-22, wherein the method further comprises heating the holding structure alignment members to change the shape of the holding structure alignment member to secure the positions of the electrodes within the holding structure.

27. A partially or wholly fabricated electrochemical cell comprising a first electrode and an electrically insulating separator layer;the first electrode comprising an electrode body, a first current collector tab,and a second current collector tab, the electrode body comprising an electrode active material layer, andwherein the first and second current collector tabs protrude from the electrode body and the first current collector tab and the second current collector tab are located at opposing ends of the electrode body.

28. The partially or wholly fabricated electrochemical cell of claim 27, wherein the electrode body is substantially rectangular and the first current collector tab is located substantially diagonally opposite the second current collector tab.

29. The partially or wholly fabricated electrochemical cell of claim 27 or claim 28, wherein the first current collector tab and the second current collector tab are connected by a current collector layer extending across the electrode body, and wherein the current collector layer and the electrically insulating separator layer sandwich the electrode active material layer.

30. The partially or wholly fabricated electrochemical cell of claim 27, claim 28, or claim 29, wherein the partially or wholly fabricated electrochemical cell comprises a second electrode, the second electrode comprising a substantially rectangular electrode body, and a first current collector tab protruding from the electrode body, and the electrode body comprises an electrode active material layer.

31. The partially or wholly fabricated electrochemical cell of claim 30, wherein the second electrode comprises a second current collector tab protruding from the electrode body,wherein the first current collector tab of the second electrode is located substantially diagonally opposite the second current collector tab of the second electrode.

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