Electrochemical cell enclosure insulation

Abstract

The present inventions relate to methods, devices, systems, apparatuses, controllers, software, and designs associated with cell assembly disposed in an enclosure to generate an energy manipulation device such as a battery. The architecture of the cell assembly in conjunction with the enclosure, may be designed to maximize energy density with respect to a cavity of a target device in which the energy manipulation device is destined to fit in. The enclosure can comprise a nonconductor insulator and / or seal material, e.g., to increase durability and use of the energy manipulation device.

Description

Attorney Docket No. ENX-016Q.WOELECTROCHEMICAL CELL ENCLOSURE INSULATIONPRIORITY APPLICATIONS

[0001] This application claims priority to U.S. Provisional Patent Application No. 63 / 772,084, filed on March 14, 2025, which is incorporated herein by reference in its entirety.BACKGROUND

[0002] The present invention relates to methods and structures such as electrode assemblies for use in energy manipulation (e.g., storage and / or release) devices such as batteries, to energy manipulation devices employing such structures, and to methods for manufacturing such structures and energy manipulation devices such as batteries. In various examples, the present invention relates to protective structural components of these devices (e.g., secondary batteries), and methods of assembly and / or manufacture, e.g., to minimize degradation of these device (e.g., secondary battery assemblies) overtime. In some embodiments, the present invention relates to protective structural components of secondary batteries, and methods of assembly, to minimize degradation of secondary battery assemblies over time.

[0003] Batteries such as lithium-ion secondary batteries are a type of energy manipulation (e.g., storage) device having electrochemical cells (also referred to as “cells” herein) in which carrier ions (e.g., such as lithium, sodium, potassium, calcium, or magnesium ions) travel between a cathode structure and an anode structure through an electrolyte within each electrochemical cell (e.g., voltaic cell) abbreviated herein as “cell.” The anode structure and cathode structure in the cell are separated by a gap. The cell may include a separator structure. The separator structure may be incorporated in the cell assembly during assembly of the battery and during battery operation. Anode and cathode current collectors pool electric current from the respective active electrochemical electrodes and enable transfer of the current to the environment outside the battery. The cathode and anode structures may include cathodically active material layers and anodically active material layers, respectively. The cathodically active material layers of the cathode structure may comprise a cathodically active material selected from transition metal oxides, transition metal sulfides, transition metal nitrides, lithium-transition metal oxides, lithium-transition metal sulfides, and lithium-transition metal nitrides. Suitable cathodically active materials include LiCoO2, LiNio5Mn1.5O4, Li(NixCoyAlz)O2, LiFePO4, Li2MnO4, and V2O5. Suitable anodically active material layers of the anode structures may comprise anodically active silicon, tin, aluminum, an oxide, a nitride, or an alloy thereof. Other suitable cathodically active materials and anodically active materials are described herein. The cathode structure, separator structure, and anode structure stack, may be referred to herein as a “unit cell.” At times, multiple unit cellsAttorney Docket No. ENX-0160.WOare arranged adjacently and make up part of the interior assembly of a secondary battery. The unit cells may be electrically coupled to one another. For example, each unit cell may be electrically coupled (e.g., in parallel) to at least one other unit cell in the arrangement.

[0004] There are a number of shortcomings related to such energy manipulation devices, their use, and / or the process of making these devices. The interior assembly of such devices (e.g., lithium-ion secondary batteries) are commonly enclosed within an enclosure such as a pouch, which can be sealed around a perimeter. The interior assembly may comprise at least one unit cell, or multiple unit cells electrically coupled (e.g., in parallel) with one another. The unit cells may be stacked in a direction parallel to a particular face of the (e.g., secondary battery) enclosure. Each unit cell may additionally comprise a nonconductor along an edge of the unit cell. This nonconductor may comprise a ceramic material. In some implementations, the sealing of the pouch around the perimeter is done via heat sealing, e.g., and pressing. In some embodiments, the sealing of the pouch creates one or more “flaps” around the perimeter. At times, the enclosure (e.g., the pouch) material is a multi-layer film that comprises a metallic layer between two polymer layers. This metallic layer may be electrically conductive. An enclosure (e.g., pouch) material can be “aluminum laminated film,” which is an aluminum metallic layer that is laminated between two polymer layers, such as polyamide or polypropylene. The application of the enclosure (e.g., pouch) material on the cell assembly (e.g., of the secondary battery) can cause problems. At times, the final processing operations of the enclosure (e.g., pouch) material requires trimming the “flaps” after sealing, which exposes a cross-sectional surface of the metallic layer of the pouch material to the external environment and reactive species such as ambient chemicals or reactive agents (e.g., oxygen, water, etc.). The reactive nature of the exposed metallic layer with such agents may lead to degradation reactions overtime that can adversely affect the structural integrity and / or the electrochemical performance of the device, e.g., the secondary battery. In some embodiments, this includes corrosion, short circuitry, reduced battery performance, or any combination thereof. The invention herein aims to prolong the lifespan of the secondary battery, e.g., by covering any exposed enclosure (e.g., pouch) material layers with a nonconductor (e.g., sealant). The nonconductor may protect the enclosure (e.g., pouch) material layers from outside forces, e.g., corrosion.TECHNICAL FIELD OF INVENTION

[0005] The present disclosure relates to enclosing electrochemical cell assemblies in an enclosure, insulating (e.g., and sealing) the edges of the enclosure to increase the durability of the energy manipulation device, e.g., battery. The present disclosure relates to insulating (e.g.,Attorney Docket No. ENX-0160.WOand sealing) the enclosure by a nonconductor, which may increase safety parameters of the device. The insulation can include an electrical insulation, a thermal insulation, a physical insulation, or any combination thereof.SUMMARY

[0006] In some aspects, the present disclosure resolves one or more of the aforementioned hardships and / or shortcomings. In some embodiments, the present disclosure provides solutions to curtail the aforementioned hardships and / or shortcomings. The solutions include method(s), device(s), apparatus(es), system(s), and / or design(s). In some aspects, the present inventions relate to method(s), device(s), apparatus(es), system(s), and design(s), utilized for a battery comprising cell(s). Methods, apparatuses, devices, program instructions, and structures, are disclosed herein to reduce the amount of adverse effects on the battery (e.g., shorting). The reduction of adverse effects to the battery may increase the safety and lifespan of an energy manipulation device (e.g., battery), e.g., during its prescribed use.

[0007] In some aspects, the energy manipulation device comprises a cell assembly enclosed in an enclosure. The device may comprise an enclosure generated from portions sealed together to enclosure the cell assembly in a central body, the enclosure having a seal extending from the central body. The enclosure may comprise at least one electrically conductive layer. The conductive layer(s) may be exposed from an edge of the enclosure, e.g., along its seal portion. The seal may be folded onto sides of the central body, e.g., as folded flaps. The sides may comprise three sides. One side may remain unfolded to generate a terrace. The cell assembly may comprise certain busbar arrangements to minimize the footprint of the device and maximize its energy density, e.g., with respect to a cavity of the target device in which the energy manipulation device (e.g., battery) is destined to be incorporated in. The busbars may allow terminal tabs of the cell assembly to emerge at a lateral side of the cell assembly having the smallest fundamental length scale (FLS), the lateral side being other than the height of the cell assembly. The terminal tabs may emerge along the stacking axis, or perpendicular to the stacking axis, e.g., such that a sacrificial volume in the target device cavity will be minimized, the sacrificial volume being defined by a surface area of the terrace and by a height of the enclosure. The edge of the enclosure may comprise a conductive material, e.g., a metallic layer. The metallic layer may contact the terminal tabs, e.g., and short. The enclosure may be designed to include a nonconductor (e.g., a nonconductor seal) to hinder (e.g., prevent) such short. The nonconductor may be one or more sections of the exposed edge. The nonconductor may increase the durability and / or safety of the device, e.g., by providing shock absorption properties such as by acting as a cushion. The nonconductor may increase the durability and / orAttorney Docket No. ENX-016Q.WOsafety of the device, e.g., by aiding in mending defects such as cracks, dislocations, small (e.g., micro) cavities, tears, punctures, or any combination thereof.

[0008] In another aspect, a device for energy manipulation, the device comprises: an electrode assembly (e.g., cell assembly) comprising an electrode separated from a counter-electrode by a gap, the electrode and counter electrode being stacked along a stacking axis; and (A) the electrode assembly has consecutive sides, the electrode being coupled with an electrode busbar, the electrode busbar being disposed along at least two of the consecutive sides, (B) the counter-electrode is coupled with a counter-electrode busbar, the counter-electrode busbar having a portion folded upon itself, (C) the electrode assembly being disposed in an enclosure comprising a conductive layer, the enclosure enclosing the electrodes assembly to generate a central body of the enclosure, the enclosure comprising flaps disposed at a periphery of the central body, the flaps collectively bordering and encircling the periphery of the enclosure along a cross section of the enclosure, each of the flaps having an exposed edge exposing a conductive edge of the conductive layer, at least one flap of the flaps contacting a side of the central body, the at least one flap being coupled with a nonconductor to insulate the exposed edge of the flap, (D) the electrode assembly being coupled with a terminal tab extending from the electrode assembly internal to the enclosure, to an ambient environment external to the enclosure, at least a portion of the terminal tab being coupled with the nonconductor to insulate the at least the portion of the terminal tab, (E) the device is coupled with the nonconductor to insulate the conductive edge of the enclosure from a portion of the terminal tab external to the enclosure, or (F) any combination of (A), (B), (C), (D), and (E). In some embodiments, the electrode assembly has the consecutive sides, the electrode being coupled with the electrode busbar, the electrode busbar being disposed along the at least two of the consecutive sides. In some embodiments, the electrode busbar is disposed along at least three of the consecutive sides. In some embodiments, the electrode assembly has a shape of a rectangular prism. In some embodiments, the consecutive sides exclude a side type having the largest surface area among side types of the enclosure. In some embodiments, the electrode busbar extends across a fundamental length scale (FLS) of one side of the consecutive sides. In some embodiments, the electrode busbar extends across the FLS of at most one side of the consecutive sides. In some embodiments, the electrode busbar extends across a portion of the FLS of one side of the consecutive sides. In some embodiments, the electrode busbar extends across a first FLS portion of one side of the consecutive sides, and extends across a second FLS portion of a second side of the consecutive sides. In some embodiments, the electrode busbar extends across a first FLS portion of one side of the consecutive sides, and extends across a secondAttorney Docket No. ENX-0160.WOFLS portion of a second side of the consecutive sides. In some embodiments, the electrode busbar extends across a first FLS portion of one side of the consecutive sides, an FLS of a second side of the consecutive sides, and a second FLS portion of a third side of the consecutive sides. In some embodiments, the consecutive sides comprise a first side shorter than a second side, and the nonconductor extends across a FLS of the second side and at least a consecutive portion of the first side. In some embodiments, the consecutive sides comprise a first side shorter than a second side, and the nonconductor extends across a FLS of the first side and at least an FLS portion of the second side. In some embodiments, the electrode assembly is coupled with the counter-electrode busbar, the counter-electrode busbar having the portion folded upon itself. In some embodiments, the counter-electrode busbar has the portion folded upon itself in a U-turn like shape. In some embodiments, the electrode busbar and a counter-electrode busbar overlap at least in part in a direction, the counter-electrode busbar being coupled with the electrode assembly, the electrode busbar having a polarity opposing that of the counter-electrode busbar. In some embodiments, the direction (i) is a stacking direction along the stacking axis, or (ii) is a lateral direction normal to the stacking direction. In some embodiments, the nonconductor comprises a resin, a polymer, any plurality of types thereof, or any combination thereof. In some embodiments, the nonconductor is a tape. In some embodiments, the tape is a non-conductive tape. In some embodiments, the nonconductor comprises a thermosetting material, a tacky material, a shrinkwrap, a foam, any plurality of types thereof, or any combination thereof. In some embodiments, the nonconductor comprises a transparent material, an opaque material, or any combination thereof. In some embodiments, the electrode assembly is disposed in the enclosure comprising the conductive layer, the enclosure enclosing the electrodes assembly to generate the central body of the enclosure, the enclosure comprising the flaps disposed at the periphery of the central body, the flaps collectively bordering and encircling the periphery of the enclosure along the cross section of the enclosure, each of the flaps having the exposed edge exposing the conductive edge of the conductive layer, at least one flap of the flaps contacting the side of the central body, the at least one flap being coupled with the nonconductor to insulate the exposed edge of the flap. In some embodiments, the nonconductor is a layer. In some embodiments, the cross section is of a rectangular shape. In some embodiments, insulation by the nonconductor comprises electrical insulation, thermal insulation, chemical insulation, physical insulation, or any combination thereof. In some embodiments, insulation by the nonconductor comprises electrical insulation. In some embodiments, the flaps of sides of the central body of the enclosure encircling a first side type having the largest surface area, the sides constituting (a) all the sides around the firstAttorney Docket No. ENX-016Q.WOside type, or (b) all the sides around the first side type except for a second side of a second side type different from the first side type. In some embodiments, the electrode assembly is coupled with at least one terminal tab, and wherein the at least one terminal tab emerges from the enclosure at the second side, e.g., from the terrace extending from the second side. In some embodiments, the electrode assembly is coupled with the terminal tab extending from the electrode assembly internal to the enclosure, to an ambient environment external to the enclosure, at least the portion of the terminal tab being coupled with the nonconductor to insulate the at least the portion of the terminal tab. In some embodiments, insulation by the nonconductor comprises electrical insulation, thermal insulation, chemical insulation, physical insulation, or any combination thereof. In some embodiments, insulation by the nonconductor comprises electrical insulation. In some embodiments, the terminal tab is an electrode terminal tab coupled with the electrode, the counter-electrode being coupled with a counter-electrode terminal tab extending from the electrode assembly internal to the enclosure, to the ambient environment external to the enclosure, at least the portion of the counter-electrode terminal tab being coupled with the nonconductor to insulate the at least the portion of the counter-electrode terminal tab. In some embodiments, the counter-electrode terminal tab and the electrode terminal tab emerge from one side of the enclosure. In some embodiments, the device is coupled with the nonconductor to insulate the conductive edge of the enclosure from the portion of the terminal tab external to the enclosure. In some embodiments, the nonconductor is disposed between the conductive edge of a flap and the terminal tab, the flap being of the flaps. In some embodiments, the terminal tab is an electrode terminal tab coupled with the electrode, the nonconductor insulates the conductive edge of the enclosure from a portion of a counterelectrode terminal tab external to the enclosure, the counter-electrode being coupled with the counter-electrode terminal tab that extends from the electrode assembly internal to the enclosure, to an ambient environment external to the enclosure, at least a portion of the counter-electrode terminal tab being coupled with the nonconductor to insulate the at least the portion of the counter-electrode terminal tab. In some embodiments, insulation by the nonconductor comprises electrical insulation, thermal insulation, chemical insulation, physical (e.g., mechanical) insulation, or any combination thereof. In some embodiments, insulation by the nonconductor comprises electrical insulation. In some embodiments, the electrode assembly comprise unit cells, each of the unit cells comprising the electrode separated from the counterelectrode by the gap. In some embodiments, the unit cells are stacked along the stacking axis. In some embodiments, the unit cells are at least about 10, 50, 100, 150, 200, 250, or 300 unit cells. In some embodiments, the electrode comprises an electrode current collector coveredAttorney Docket No. ENX-016Q.WOwith electrode active material at opposing sides of the electrode current collector. In some embodiments, the electrode comprises a counter-electrode current collector covered with counter-electrode active material at opposing sides of the counter-electrode current collector. In some embodiments, the gap comprises a separator configured to allow charge carriers to pass therethrough. In some embodiments, the electrode busbar is configured to electrically connect each of the electrode of the unit cells. In some embodiments, the counter-electrode busbar is configured to electrically connect each of the counter-electrodes of the units cells. In some embodiments, the electrode comprises electrode active material comprising silicon. In some embodiments, the electrode assembly is of a secondary battery. In some embodiments, the device comprises charge carriers comprising alkali, alkali earth, or a combination thereof. In some embodiments, the charge carriers comprise lithium. In some embodiments, the conductive edge comprises at least one metallic layer. In some embodiments, the conductive edge comprises at least one organic layer. In some embodiments, the at least one metallic layer is positioned adjacent to one or more organic layers. In some embodiments, the at least one metallic layer is positioned between at least two organic layers. In some embodiments, the at least one metallic layer comprises an elemental metal, a metal alloy, a plurality of types thereof, or any combination thereof. In some embodiments, the conductive layer is configured to conduct electricity and / or heat. In some embodiments, the conductive layer is configured to conduct electricity. In some embodiments, the conductive layer can undergo a reaction with a reactive species present in an ambient environment. In some embodiments, the reaction leads to corrosion of the conductive layer. In some embodiments, the conductive layer can electrically short on contact with the terminal tab. In some embodiments, the reactive species causes material degradation, electrical short, or any combination thereof, when reacting (i) with the tab, (ii) with the conductive layer, or (iii) with the tab and with the conductive layer. In some embodiments, the degradation comprises corrosion. In some embodiments, the reactive species comprises water, oxygen, acid, or hydrogen sulfide. In some embodiments, the conductive edge comprises a cut edge. In some embodiments, the cut edge is indicative of a mechanical cutting and / or laser cutting. In some embodiments, a portion of the conductive edge comprises a region along one side of the central body. In some embodiments, the nonconductor is disposed along at least two, or at least three regions of the conductive edge portion adjacent to respective sides of the central body. In some embodiments, the regions are consecutive such that they border each other. In some embodiments, the sides are consecutive such that they border each other. In some embodiments, a region of the conductive edge comprises a perimeter of a seal of the enclosure, the flaps comprise the seal. In some embodiments, the region of the conductive edgeAttorney Docket No. ENX-016Q.WOcomprises a region adjacent to the terminal tab. In some embodiments, the region of the conductive edge comprises discrete segments being separated from each other by a gap. In some embodiments, the region of the conductive edge is of the flaps. In some embodiments, the nonconductor extends along one or more sides of the central body having a surface area smaller than a side of the central body having the largest surface area. In some embodiments, the nonconductor extends along all sides of the enclosure (a) other that a side type having the largest surface area and (b) other than a side having a flap that connects to a terrace side at an edge of the side (e.g., to form a terrace), and is otherwise uncoupled with the terrace side of the central body, the terrace side having a surface area smaller than another side type of the central body having the largest surface area. In some embodiments, the terrace side of the central body is of a type having the smallest surface area among side types of the central body. In some embodiments, the nonconductor extends along sides (e.g., all sides) of the enclosure different from the side type having the largest surface area. In some embodiments, the nonconductor extends along the enclosure (e.g., as a shrink-wrap cover), the enclosure including the conductive edge. In some embodiments, the busbar comprises at least two sections that are coupled together. In some embodiments, coupling of the two sections together comprise welding, adhering, soldering, brazing, clinching, hemming, fastening, a plurality of types thereof, or any combination thereof. In some embodiments, welding comprises laser welding, spot welding, or any combination thereof. In some embodiments, adhering is at least in part using a conductive adhesive. In some embodiments, the fastening comprises a mechanical fastener comprising a screw, a bolt, a nut, a riven, a clamp, a snap fit, any plurality of types thereof, or any combination thereof. In some embodiments, the nonconductor is disposed between the terminal tab and the conductive edge such that the nonconductor does not contact the terminal tab, the nonconductor comprising (a) a first portion contacting at least a portion of the terminal tab, (b) a second portion contacting at least a portion of the conductive edge on the side of the enclosure from which the terminal tab emerges, (c) a third portion disposed in an intermediate region between the terminal tab and the conductive edge coupled with a side of the central body from which the terminal tab emerges out of the enclosure, or (d) any combination of (a), (b), and (c). In some embodiments, the nonconductor is configured to seal from an ambient environment. In some embodiments, the seal comprises a hermetic seal. In some embodiments, the seal comprises a liquid tight seal, a solid tight seal, a gel-tight seal, a gas tight seal, or any combination thereof. In some embodiments, the nonconductor comprises tape. In some embodiments, the tape comprises a single-sided tape, double-sided tape, a flexible tape (e.g., in a form of a band), or any combination thereof. In some embodiments, the tape includes aAttorney Docket No. ENX-016Q.WOmaterial comprising a polymer, a resin, an organic, a composite, a silicon-based material, an elastomeric, a thermoplastic, a plurality of types thereof, or any combination thereof. In some embodiments, the silicon-based material comprises a silicon elastomer, a silicon resin, a siloxane polymer (polysiloxane), any plurality of types thereof, or any combination thereof. In some embodiments, the material of the tap comprises a polyester, an acrylic, any plurality of types thereof, or any combination thereof. In some embodiments, the material of the tape comprises a water-based material, an organic solvent-based material, a hot-melt material, an electromagnetic curable material, a pressure sensitive material, a plurality of types thereof, or any combination thereof. In some embodiments, the polyester comprises a polyethylene terephthalate, polybutylene terephthalate, a polyethylene naphtholate, any plurality of types thereof, or any combination thereof. In some embodiments, the tape comprises a polyimide (e.g., Kapton), polyethylene, a polypropylene, any plurality of types thereof, or any combination thereof. In some embodiments, the nonconductor comprises glue. In some embodiments, the glue comprises a heat-activated adhesive, a pressure-sensitive adhesive, an electromagnetic radiation activated adhesive, a thermoplastic adhesive, any plurality of types thereof, or any combination thereof. In some embodiments, the glue comprises an epoxy, an acrylic, a polyimide, any plurality of types thereof, or any combination thereof. In some embodiments, the nonconductor comprises a photosensitive material. In some embodiments, the photosensitive material is sensitive to ultraviolet radiation, infrared radiation, visible light, or any combination thereof. In some embodiments, the photosensitive material is sensitive to ultraviolet radiation. In some embodiments, the enclosure comprises an enclosure seal configured to seal the electrode assembly in the enclosure, the terminal tab extending from the electrode assembly through the enclosure seal to an external environment of the enclosure. In some embodiments, the enclosure seal is configured to couple two or more portions of the enclosure. In some embodiments, the portions of the enclosure comprise a cup (e.g., cavity) and a lid of the cup. In some embodiments, coupling the lid and the cup generates the central body and the flaps. In some embodiments, the flaps are trimmed to expose the conductive edge. In some embodiments, the seal is a hermetic seal. In some embodiments, the seal comprises an adhesive configured to adhere the cup with the lid. In some embodiments, the seal is devoid of an adhesive configured to adhere the cup with the lid. In some embodiments, the seal is indicative of the cup being coupled with the lid using heat and / or pressure. In some embodiments, the seal is indicative of the cup being coupled with the lid at least in part by altering material properties of the cup and the lid, at least in part in a region of the seal. In some embodiments, the seal is indicative of the cup being coupled with the lid at least in part usingAttorney Docket No. ENX-0160.WOtrimming. In some embodiments, the trimming comprises one or more punching methodologies. In some embodiments, the trimming comprises mechanical cutting, laser cutting, any plurality of types thereof, or any combination thereof. In some embodiments, materials of the seal and of the nonconductor are different. In some embodiments, different is at least in part by their chemical makeup, physical state, texture, or any combination thereof, at a given temperature and pressure. In some embodiments, the given temperature and pressure is at an ambient temperature of the ambient environment. In some embodiments, the given temperature is from about -20 Celsius (°C) to about 60°C. In some embodiments, the nonconductor acts to condition an impact before reaching the electrode assembly, the impact being exerted on the enclosure from conditions external to the enclosure. In some embodiments, the conditions comprise physical impact, chemical impact, or any combination thereof. In some embodiments, the physical impact comprises temperature change, excessive force on a location, or any combination thereof, the excessive force capable of damaging the enclosure, the temperature change capable of damaging the enclosure and / or damaging cell assembly. In some embodiments, the temperature change is capable of causing a thermal runaway reaction in the cell assembly. In some embodiments, the nonconductor comprises an elastic material. In some embodiments, the nonconductor comprises a cushion.

[0009] In another aspect, a method of using the device of any of the above devices, the method comprises: (a) providing the device and (b) using the device for the energy manipulation. In some embodiments, using the device comprises storing, transporting, servicing, upgrading, buffering, forming a passivation layer, and / or cycling the device between charge and discharge states of the cell assembly.

[0010] In another aspect, an apparatus for the energy manipulation, the apparatus comprises: one or more controllers configured to (a) operatively couple with the device of any of the above devices, and (b) direct one or more components to use, the one or more controllers being operatively coupled with the one or more components. In some embodiments, use of the device comprises storing, transporting, servicing, upgrading, buffering, forming a passivation layer, and / or cycling the device between charge and discharge states of the cell assembly. In some embodiments, the one or more controllers comprise, or are operatively coupled with, a communication system and / or comprise connection configured to couple with a power source. In some embodiments, the connection is an electrical connection. In some embodiments, the power source is an electrical grid.

[0011] In another aspect, non-transitory computer-readable program instructions physically inscribed on at least one media, the program instructions, when read by one or more processorsAttorney Docket No. ENX-016Q.WOoperatively coupled with the device of any of the above devices, cause the one or more processors to execute one or more operations for using the device for the energy manipulation. In some embodiments, using the device comprises storing, transporting, servicing, upgrading, buffering, forming a passivation layer, and / or cycling the device between charge and discharge states of the cell assembly.

[0012] In another aspect, a method of generating the device of any of the above devices, the method comprising manufacturing the device. In some embodiments, the manufacturing comprises adding the nonconductor to generate the device. In some embodiments, adding the nonconductor comprises coating, spraying, brushing, dipping, immersion, curing, temperature conditioning, applying pressure, applying a mask, additive manufacturing, any plurality of types thereof, or any combination thereof.

[0013] In another aspect, an apparatus for the energy manipulation, the apparatus comprising one or more controllers configured to (a) operatively couple with one or more components configured to manufacture the device of any of the above devices, and (b) direct the one or more components to execute one or more operations to manufacture the device. In some embodiments, the one or more operations comprise adding the nonconductor to generate the device. In some embodiments, adding the nonconductor comprises coating, spraying, brushing, dipping, immersion, curing, temperature conditioning, applying pressure, applying a mask, additive manufacturing, any plurality of types thereof, or any combination thereof. In some embodiments, the one or more controllers comprise, or are operatively coupled with, a communication system and / or connection configured to couple with a power source. In some embodiments, the connection is an electrical connection. In some embodiments, the power source is an electrical grid.

[0014] In another aspect, non-transitory computer-readable program instructions physically inscribed on at least one media, the program instructions, when read by one or more processors operatively coupled with the device of any of the above devices, cause the one or more processors to execute one or more operations for manufacturing the device for use in the energy manipulation. In some embodiments, the one or more operations comprise adding the nonconductor to generate the device. In some embodiments, adding the nonconductor comprises coating, spraying, brushing, dipping, immersion, curing, temperature conditioning, applying pressure, applying a mask, additive manufacturing, any plurality of types thereof, or any combination thereof.

[0015] In another aspect, a battery comprises: an electrode assembly comprising unit cells stacked in a stacking direction; a housing (e.g., an enclosure) enclosing the electrode assembly,Attorney Docket No. ENX-016Q.WOthe housing comprising (a) a lateral face type comprising a first lateral face and an opposing a second lateral face, and (b) a traverse face type comprising a first traverse plane and a second traverse plane, the lateral face type being normal, or substantially normal, to the traverse face type, the stacking direction being from the first traverse plane to the second traverse plane, the first traverse plane comprising electrical contacts of the battery contacting an ambient environment external to the housing, the housing sealing the electrode assembly from the ambient environment; and a nonconductor (an insulating material) disposed on the second traverse plane, the nonconductor being electrically insulating. In some embodiments, the battery is a secondary battery. In some embodiments, the battery comprises lithium ions. In some embodiments, a unit cell of the unit cells comprises an anode comprising silicon. In some embodiments, each unit cell of the unit cells comprises an anode structure, a separator structure, and a cathode structure. In some embodiments, the unit cells comprise at least two-unit cells that are electronically coupled in parallel. In some embodiments, each unit cell of the unit cells is electronically coupled in parallel with another unit cell of the unit cells. In some embodiments, the housing comprises a flap that is electrically conductive. In some embodiments, the flap comprises an elemental metal, a metal alloy, or a composite material. In some embodiments, the flap comprises a material that can react with at least one reactive agent in the ambient environment. In some embodiments, reaction of the material with the at least one reactive agent over a lifetime of the battery adversely affects the battery. In some embodiments, reaction of the material with the at least one reactive agent over the lifetime of the battery adversely affects performance of the battery. In some embodiments, when exposed to the ambient environment over a lifetime of the battery, the flap degrades, shorts, corrodes, or any combination thereof. In some embodiments, the ambient environment comprises a reactive agent that reacts with the flap over the lifetime of the battery. In some embodiments, the reactive agent comprises water, oxygen, or hydrogen sulfide. In some embodiments, the housing comprises a flap disposed on the traverse face type. In some embodiments, the flap is disposed at the second traverse plane. In some embodiments, the housing comprises a seal that seals the flap from the ambient environment. In some embodiments, the housing comprises a seal that seals the flap from at least one reactive agent in the ambient environment, the seal being disposed on the traverse face type such that electricity flowing through the electrical contacts is unobstructed. In some embodiments, the housing comprises a seal that seals the flap from at least one reactive agent in the ambient environment. In some embodiments, the reactive agent comprises water, oxygen, or hydrogen sulfide. In some embodiments, the housing comprises a seal that seals the flap from at least one reactive agent in the ambientAttorney Docket No. ENX-0160.WOenvironment such that the flap does not deteriorate to an extent that harms performance of the battery over its lifetime. In some embodiments, the housing comprises flaps disposed on the traverse face type. In some embodiments, at least two of the traverse face types have different flaps. In some embodiments, difference can be in material content and / or in relative location. In some embodiments, the seal comprises a polyimide, polyethylene, or polypropylene. In some embodiments, the seal comprises glue. In some embodiments, the seal comprises a tape. In some embodiments, the seal comprises a photosensitive material. In some embodiments, the photosensitive material is sensitive in an ultraviolet spectrum range. A method for fabricating the battery of any of the above batteries, the method comprising using one or more methodologies to fabricate the battery. In some embodiments, the one or more methodologies comprise coating, spraying, applying a mask, or additive manufacturing. In some embodiments, coating comprises spray-coating.

[0016] In another aspect, an apparatus for fabricating the battery of any of the above batteries, the apparatus comprises: at least one controller configured to direct one or more devices utilized in the fabrication, and direct the one or more devices to use one or more methodologies to fabricate the battery. In some embodiments, the one or more methodologies comprise coating, spraying, applying a mask, or additive manufacturing. In some embodiments, coating comprises spray-coating. In some embodiments, the at least one controller is configured to operatively couple to a power source and / rot with a communication platform.

[0017] In another aspect, one or more non-transitory computer readable media comprising program instruction physically inscribed thereon, the program instructions, when read by one or more processors operatively coupled with one or more devices utilized in fabrication of the battery of the above batteries, are configured to execute, or direct execution of, one or more operations associated with the fabrication. In some embodiments, the fabrication comprises coating, spraying, applying a mask, or additive manufacturing. In some embodiments, the coating comprises spray-coating.

[0018] In another aspect, a method associated with the battery of any of the above batteries, the method comprises: (a) providing any of the battery, and (b) storing the battery, maintaining the battery, transporting the battery, pre-charging the battery, or using the battery for its intended purpose. In some embodiments, the intended purpose comprises conductive electricity through the electrical contacts.

[0019] In another aspect, an apparatus for directing a method associated with the battery of the above batteries, the apparatus comprises at least one controller configured to direct one or more components associated with the battery for its storage, maintenance, transportation, preAttorney Docket No. ENX-0160.WOcharging, or usage for its intended purpose. In some embodiments, the intended purpose comprises conductive electricity through the electrical contacts. In some embodiments, the at least one controller is configured to operatively couple to a power source and / rot with a communication platform.

[0020] In another aspect, one or more non-transitory computer readable media comprising program instruction physically inscribed thereon, the program instructions, when read by one or more processors operatively coupled with one or more devices utilized in a method associated with the battery of any of the above batteries, the one or more processors being configured to execute, or direct execution of, one or more operations associated with the method comprising storing the battery, maintaining the battery, transporting the battery, pre-charging the battery, or using the battery for its intended purpose. In some embodiments, the intended purpose comprises conductive electricity through the electrical contacts. In some embodiments, each of the lateral face type comprises a surface area larger than that of each of the traverse face type. In some embodiments, the anode structure, the separator structure, and the cathode structure of each unit cell are stacked in a direction parallel to the lateral face type. In some embodiments, each unit cell comprises a nonconductor disposed at an edge of the unit cell. In some embodiments, the nonconductor comprises a ceramic material.

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

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

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

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

[0025] In other aspects, methods, systems, apparatuses (e.g., controller(s)), and / or non-transitory computer-readable program instructions (e.g., software) that implement any of the devices disclosed herein and / or any operation of these devices. In some embodiments, the program instructions are inscribed on at least one medium (e.g., on a medium or on media).Attorney Docket No. ENX-0160.WO

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

[0027] In another aspect, an apparatus comprises at least one controller configured (e.g., programmed) to implement (e.g., effectuate), or direct implementation of the method, process, and / or operation disclosed herein. In some embodiments, the at least one controller implements any of the methods, processes, and / or operations disclosed herein.

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

[0029] In another aspect, a system comprises an apparatus and at least one controller configured (e.g., programmed) to direct operation of the apparatus, wherein the at least one controller is operatively coupled with the apparatus. In some embodiments, the apparatus includes any apparatus or device disclosed herein. In some embodiments, the at least one controller implements, or direct implementation of, any of the methods disclosed herein. In some embodiments, the at least one controller directs any apparatus (or component thereof) disclosed herein. In some embodiments, at least two operations (e.g., instructions) of the apparatus are directed by the same controller. In some embodiments, at least two operations (e.g., instructions) of the apparatus are directed by different controllers. In some embodiments, at least two operations (e.g., instructions) are carried out by the same processor and / or by the same sub-computer software product. In some embodiments, at least two of operations (e.g., instructions) are carried out by different processors and / or by different sub-computer software products.Attorney Docket No. ENX-0160.WO

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

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

[0032] In another aspect, a method comprises executing one or more operations associated with at least one configuration of the mechanism(s) (e.g., device(s)) disclosed herein.

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

[0034] In another aspect, at least one controller is associated with the methods, devices, and software disclosed herein. In some embodiments, the at least one controller comprises at least one connector configured to connect to a power source. In some embodiments, the at least one controller being configured to operatively couple with a power source at least in part by (I) having a power socket and / or (II) being configured for wireless power transfer using inductive charging. In some embodiments, the at least one controller comprises a non-volatile memory, e.g., a solid-state device (SSD) such as a FLASH memory. In some embodiments, the at least one controller is included in, or comprises, a hierarchical control system. In some embodiments, the hierarchical control system comprises at least three hierarchical control levels. In some embodiments, the at least one controller is included in a control system disclosed herein. In some embodiments, the at least one controller is configured to control at least one other component of a mechanism (e.g., system, device, or apparatus) disclosed herein. In some embodiments, the device disclosed herein is a component of a system, and wherein the at least one controller is configured to (i) operatively couple to another component of the system and (ii) direct operation of the other component. In some embodiments, the at least one controller is configured to direct operation of the other component at least in part for participation of the other component in a method disclosed herein.Attorney Docket No. ENX-0160.WO

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

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

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

[0038] Additional aspects and advantages of the present disclosure will become readily apparent to those skilled in this art from the following detailed description, wherein only illustrative embodiments of the present disclosure are shown and described. As will be realized, the present disclosure is capable of other and different embodiments, and its several details are capable of modifications in various obvious respects, all without departing from the disclosure. Accordingly, the drawings and description are to be regarded as illustrative in nature, and not as restrictive.INCORPORATION BY REFERENCE

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

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

[0041] The novel features of the present disclosure are set forth with particularity in the appended claims. Each of the figures disclosed herein is shown in accordance with some implementations of the subject matter of the disclosure. A better understanding of the features and advantages of the present disclosure will be obtained by reference to the following detailedAttorney Docket No. ENX-0160.WOdescription that sets forth illustrative embodiments, in which the principles of the present disclosure are utilized, and the accompanying drawings or figures (also “Fig.” and “Figs.” herein), of which:

[0042] Fig. 1 is a perspective view of a secondary battery of an example embodiment;

[0043] Fig. 2 depicts a unit cell for the secondary battery of Fig. 1;

[0044] Fig. 3 depicts an example cathode structure for the unit cell of Fig. 2;

[0045] Fig. 4 depicts an anode structure for the unit cell of Fig. 2;

[0046] Fig. 5 depicts a perspective view of a buffer system;

[0047] Fig. 6 depicts an exploded view of the buffer system of Fig. 5;

[0048] Fig. 7 depicts a perspective view of an auxiliary electrode;

[0049] Fig. 8 depicts an exploded view of the auxiliary electrode of Fig. 7;

[0050] Fig. 9 is a perspective view of the auxiliary electrode of Fig. 7 at a stage in an assembly process for the auxiliary electrode of Fig. 7;

[0051] Fig. 10 is a perspective view of the auxiliary electrode of Fig. 7 at another stage in an assembly process for the auxiliary electrode of Fig. 7;

[0052] Fig. 11 is a perspective view of the auxiliary electrode of Fig. 7 at yet another stage in an assembly process that adds an extension tab to the auxiliary electrode of Fig. 7;

[0053] Fig. 12 is a perspective view of the buffer system of Fig. 5 at a stage in an assembly process for the buffer system;

[0054] Fig. 13 is a perspective view of the buffer system of Fig. 5 at another stage in an assembly process for the buffer system;

[0055] Fig. 14 is a perspective view of the buffer system of Fig. 5 at yet another stage in an assembly process for the buffer system;

[0056] Fig. 15 is a cross-sectional view of a portion of the buffer system of Fig. 14;

[0057] Fig. 16 is a perspective view of the buffer system of Fig. 5 at yet another stage in an assembly process for the buffer system;

[0058] Fig. 17 is a perspective view of the buffer system of Fig. 5 subsequent to performing a buffer process on a secondary battery;

[0059] Fig. 18 is a flow chart of a method of pre-lithiating a secondary battery with carrier ions using an auxiliary electrode;

[0060] Fig. 19 is a flow chart depicting additional details of the method of Fig. 18;

[0061] Fig. 20 is a flow chart depicting additional details of the method of Fig. 18;

[0062] Fig. 21 is a flow chart depicting additional details of the method of Fig. 18;Attorney Docket No. ENX-0160.WO

[0063] Fig. 22 illustrates the application of the seal to a secondary battery after creating a folded terrace, in accordance with some implementations of the disclosure;

[0064] Fig. 23 is an illustration of a component of a secondary battery before creating a folded terrace, in accordance with some implementations of the disclosure;

[0065] Fig. 24 illustrates a secondary battery with a folded terrace with a nonconductor layer applied to four faces of the secondary battery;

[0066] Fig. 25 is an illustration of a secondary battery with an unfolded terrace with a nonconductor applied to three faces of the device, in accordance with some implementations of the disclosure;

[0067] Fig. 26 depicts a schematic example of various cells;

[0068] Fig. 27 depicts schematic examples of folding options for energy manipulation device (e.g., battery) components, and a current collector;

[0069] Fig. 28 depicts schematic examples of devices (e.g., batteries) and cells;

[0070] Fig. 29 depicts schematic examples of cell architectures;

[0071] Fig. 30 depicts schematic exploded views of device (e.g., battery) components;

[0072] Fig. 31 depicts illustrative examples of device (e.g., battery) components;

[0073] Fig. 32 shows images of device (e.g., battery) components;

[0074] Fig. 33 is an illustration of a secondary battery in various configurations with a nonconductor applied;

[0075] Fig. 34 depicts example flow chart depicting a process for generating the device;

[0076] Fig. 35 depicts a schematic example of a control system; and

[0077] Fig. 36 depicts a schematic example of a processing system.

[0078] The figures and components therein may not be drawn to scale. Various components of the figures described herein may not be drawn to scale.DETAILED DESCRIPTION

[0079] While various embodiments of the inventions have been shown, and described herein, it will be obvious to those skilled in the art that such embodiments are provided by way of example only. Numerous variations, changes, and substitutions may occur to those skilled in the art without departing from the invention. It should be understood that various alternatives to the embodiments of the invention described herein might be employed. The various embodiments, aspects, examples, variations, alternates, and instances, disclosed herein are combinable, as appropriate.

[0080] Reference throughout the specification to “various embodiments,” “some embodiments,” “one embodiment,” “some example embodiments,” “one example embodiment,” “an example,”Attorney Docket No. ENX-0160.WOor “an embodiment” means that a particular feature, structure, or characteristic described in connection with any embodiment is included in at least one embodiment. Thus, appearances of the phrases “in various embodiments,” “in some embodiments,” “in one embodiment,” “some example embodiments,” “one example embodiment,” or “in an embodiment” in places throughout the specification are not necessarily all referring to the same embodiment.Furthermore, the particular features, structures or characteristics may be combined in any suitable manner in one or more embodiments.

[0081] Terms such as “a,” “an” and “the” are not intended to refer to only a singular entity but include the general class of which a specific example may be used for illustration. The terminology herein is used to describe specific embodiments in the present disclosure, but their usage does not delimit to the specific embodiments of the present disclosure. The term “includes” means includes but not limited to, the term “including” means including but not limited to, and the term “based on” means based at least in part on.

[0082] An immediately consecutive second feature to a first feature is devoid of another feature disposed therebetween, the features being of the same type. The feature can be a real-life feature, a calculated feature, or any other virtual feature.

[0083] When the term “about” is used in the contacts of a number, e.g., “about #,” the term includes the number.

[0084] When ranges are mentioned, the ranges are meant to be inclusive, unless otherwise specified. For example, a range between value 1 and value 2 is meant to be inclusive and include value 1 and value 2. The inclusive range will span any value from about value 1 to about value 2. The term “adjacent” or “adjacent to,” as used herein, includes “next to,” “adjoining,” “in contact with,” and “in proximity to.” When ranges are mentioned (e.g., between, at least, at most, and the like) the endpoint(s) of the range is / are also claimed. For example, when the range is from X to Y, the values of X and Y are also claimed. For example, when the range is at most Z, the value of Z is also claimed. For example, when the range is at least W, the value of Wis also claimed.

[0085] The conjunction “and / or” as used herein in “X and / or Y” - including in the specification and claims - is meant to include the options (i) X, (ii) Y, and (iii) X and Y, as applicable. The phrase “including X, and / or Y” is meant to have the same meaning as the phrase “comprising X or Y” under currently prevailing US law.

[0086] The term “operatively coupled,” “operatively configured,” or “operatively connected” refers to a first mechanism that is coupled (or connected) to a second mechanism to allow the intended operation of the second and / or first mechanism. The coupling may comprise physicalAttorney Docket No. ENX-0160.WOor non-physical coupling. The non-physical coupling may comprise signal-induced coupling (e g., wireless coupling).

[0087] The phrase “is / are structured” or “is / are configured,” when modifying an article, refers to a structure of the article that can bring about the referred result.

[0088] The symbol “*” designates the mathematical operation of multiplication, e.g., “times.”

[0089] Fundamental length scale (abbreviated herein as “FLS”) comprises any suitable scale (e.g., dimension) of an object. For example, an FLS of an object may comprise a length, a width, a height, a diameter, a spherical equivalent diameter, a diameter of a bounding circle, a diameter equivalent of a bounding sphere.

[0090] Performing a reversible first operation is understood herein to mean performing the first operation and being capable of performing the opposite operation to that first operation (e.g., which is a second operation). For example, when a controller directs reversibly opening a shutter, that shutter can also close, and the controller can optionally direct a closure of that shutter. For example, when an attractor reversibly binds to a charge carrier, that attractor can also release that charge carrier after its binding.

[0091] While the disclosure refers to a cathode as an electrode, the electrode may be an anode, as applicable.

[0092] While various portions herein may refer for simplicity to a battery as an energy manipulation device, that disclosure is extended to any another energy manipulation (e.g., storage) device, as applicable.

[0093] As noted above, implementations of the present disclosure can relate to (e.g., secondary) batteries, the structures that make up the (e.g., secondary) batteries, and the methods and processes for manufacturing the structures and batteries. As used herein, the term “anode” used in the context of a (e.g., secondary) battery may refer to the negative electrode in a (e.g., secondary) battery. “Anode material” or “anodically active” as used herein may refer to a material or materials suitable for use as the negative electrode of a (e.g., secondary) battery. The term “cathode” as used herein in the context of a (e.g., secondary) battery may refer to the positive electrode in a (e.g., secondary) battery. “Cathode material” or “cathodically active” as used herein may refer to a material or materials suitable for use as the positive electrode of a (e.g., secondary) battery. In some implementations, the term "Electrochemically active material" as used herein means anodically active or cathodically active material.

[0094] "Counter-electrode current collector" as used herein may refer to the negative or positive (anode or cathode) current collector, opposite of the electrode current collector, of a secondary battery unless the context clearly indicates otherwise.Attorney Docket No. ENX-016Q.WO

[0095] "Electrode current collector" as used herein may refer to the negative or positive (anode or cathode) current collector of a secondary battery unless the context clearly indicates otherwise.

[0096] "Electrode material" as used herein may refer to anode material or cathode material unless the context clearly indicates otherwise.

[0097] In some implementations described herein, the term “electrode” or “electrode structure” may be used to refer to either the anode or the cathode, and the term “counter-electrode” may refer to the other or opposite. For the sake of explanation, implementations may be described in terms of “electrode” and “counter-electrode.” It should be appreciated that in these implementations, the term electrode may be replaced by the term anode while the term counterelectrode may be replaced by the term cathode, as applicable. Alternatively, in these implementations, the term electrode may be replaced by the term cathode while the term counter-electrode may be replaced by the term anode, as applicable.

[0098] "Conversion chemistry active material" or "Conversion chemistry material" refers to a material that undergoes a chemical reaction during the charging and discharging cycles of a secondary battery.

[0099] "Cycle" as used herein in the context of cycling of a secondary battery between charged and discharged states refers to charging and / or discharging a battery to move the battery in a cycle from a first state that is either a charged or discharged state, to a second state that is the opposite of the first state (i.e., a charged state if the first state was discharged, or a discharged state if the first state was charged), and then moving the battery back to the first state to complete the cycle. For example, a single cycle of the secondary battery between charged and discharged states can include, as in a charge cycle, charging the battery from a discharged state to a charged state, and then discharging back to the discharged state, to complete the cycle. The single cycle can also include, as in a discharge cycle, discharging the battery from the charged state to the discharged state, and then charging back to a charged state, to complete the cycle.

[0100] "Charged state" as used herein in the context of the state of a secondary battery refers to a state where the secondary battery is charged to at least 75% of its rated capacity unless the context clearly indicates otherwise. For example, the battery may be charged to at least 80% of its rated capacity, at least 90% of its rated capacity, and even at least 95% of its rated capacity, such as 100% of its rated capacity.

[0101] "Discharge capacity" as used herein in connection with a negative electrode means the quantity of carrier ions available for extraction from the negative electrode and insertion into theAttorney Docket No. ENX-016Q.WOpositive electrode during a discharge operation of the battery between a predetermined set of cell end of charge and end of discharge voltage limits unless the context clearly indicates otherwise.

[0102] "Discharged state" as used herein in the context of the state of a secondary battery refers to a state where the secondary battery is discharged to less than 25% of its rated capacity unless the context clearly indicates otherwise. For example, the battery may be discharged to less than 20% of its rated capacity, such as less than 10% of its rated capacity, and even less than 5% of its rated capacity, such as 0% of its rated capacity.

[0103] "Reversible coulombic capacity" as used herein in connection with an electrode (i.e. , a positive electrode, a negative electrode or an auxiliary electrode) means the total capacity of the electrode for carrier ions available for reversible exchange with a counter electrode.

[0104] "Composite material" or "Composite" as used herein refers to a material which comprises two or more constituent materials unless the context clearly indicates otherwise.

[0105] "Void fraction" or "Porosity" or "Void volume fraction" as used herein refers to a measurement of the voids (i.e., empty) spaces in a material, and is a fraction of the volume of voids over the total volume of the material, between 0 and 1, or as a percentage between 0% and 100%.

[0106] "Polymer" as used herein may refer to a substance or material consisting of repeating subunits of macromolecules unless the context clearly indicates otherwise.

[0107] "Microstructure" as used herein may refer to the structure of a surface of a material revealed by an optical microscope above about 25x magnification unless the context clearly indicates otherwise.

[0108] "Microporous" as used herein may refer to a material containing pores with diameters less than about 2 nanometers unless the context clearly indicates otherwise.

[0109] "Macroporous" as used herein may refer to a material containing pores with diameters greater than about 50 nanometers unless the context clearly indicates otherwise.

[0110] "Nanoscale" or "Nanoscopic scale" as used herein may refer to structures with a length scale in the range of about 1 nanometer to about 100 nanometers.

[0111] "Pre-lithiation" or "Pre-lithiate" as used herein may refer to the addition of lithium to the active lithium content of a lithium containing secondary battery as part of the formation process prior to battery operation to compensate for the loss of active lithium.

[0112] "Longitudinal axis," "transverse axis," and "vertical axis," as used herein refer to mutually perpendicular axes (i.e., each are orthogonal to one another). For example, the "longitudinal axis," "transverse axis," and the "vertical axis" as used herein are akin to a Cartesian coordinateAttorney Docket No. ENX-0160.WOsystem used to define three-dimensional aspects or orientations. As such, the descriptions of elements of the disclosed subject matter herein are not limited to the particular axis or axes used to describe three-dimensional orientations of the elements. Alternatively stated, the axes may be interchangeable when referring to three-dimensional aspects of the disclosed subject matter.

[0113] The prescribed use of the device (e.g., battery) comprises during charge-discharge cycling, during transportation, during storage, during maintenance, during upgrade, or any combination thereof. The prescribed use (e.g., operation) of the cell assembly comprises during formation of the cell assembly, during buffering of the cell assembly, during the prescribed use of the device comprising the cell assembly or any combination thereof.

[0114] In some embodiments, the energy manipulation device may comprise at least one battery. The battery may comprise one or more cells. The battery may be a rechargeable battery, e.g., a secondary battery. The charge carriers of the battery may comprise alkali earth, alkali cations, a plurality of types of any thereof, or any combination thereof. In an example, the battery comprises charge carriers such as lithium charge carriers. In some embodiments, charge carriers may comprise carrier ions. In some embodiments, carrier ions are provided to positive electrodes and / or negative electrodes by carrier ion supply layers. Carrier ion supply layers may comprise one or more sources of lithium ions, sodium ions, potassium ions, calcium ions, magnesium ions, aluminum ions, and / or similar such ions. The battery may or may not be a polymer type battery such as a lithium polymer type battery.

[0115] Fig. 1 is a perspective view of a secondary battery 100 of an example embodiment, and Fig. 2 depicts a unit cell 200 for the secondary battery 100. The secondary battery 100 in Fig. 1 has a portion exposed showing some of the internal structures of the secondary battery, as further described below.

[0116] In some embodiments, the energy manipulation device includes at least one unit cells. The energy manipulation device may comprise a population of unit cells (e.g., also referred to herein as a “set of cells”). The device may comprise an electrode connector operatively coupled with the electrode and a counter-electrode connector operatively coupled with the counterelectrode, with operatively coupled comprising electrically connected. The electrode connector may be also referred to herein as “an electrode terminal,” and the counter-electrode connector may be also referred to herein as “a counter-electrode terminal.” The device may comprise an electrode busbar, a counter-electrode busbar, an electrode terminal operatively coupled with the electrode busbar, and a counter-electrode terminal operatively coupled with the counterelectrode busbar. The electrode and counter electrode of the unit cell are separated by eachAttorney Docket No. ENX-0160.WOother by a gap, e.g., to electrically separate the electrode from the counter-electrode. The gap may include a separator configured to (a) electrically isolate the electrode from the counter electrode and (b) allow traversal of charge carriers through the separator. In some embodiments, each unit cell of the set of cells, includes an electrode structure and a counterelectrode structure separated from each other by a gap. One or more (e.g., each) cells of the set of cells, each include a separator (e.g., separator layer) disposed in the gap. In various examples, the anodically active material layer 104 and the cathodically active material layer 106 are electrically isolated from each other by a separator layer 108. In some embodiments, the battery includes adjacent electrode sub-units. In example Fig. 1, the secondary battery 100 includes a plurality of adjacent electrode sub-units 102. Each of the electrode sub-units (e.g., 102) has a dimension in the X-axis, Y-axis and Z-axis, respectively. The X-axis, Y-axis and Z-axis are each mutually perpendicular, akin to a Cartesian coordinate system. As used herein, dimensions of each electrode sub-unit (e.g., 102) in the Z-axis may be referred to as a "height", dimensions in the Y-axis may be referred to as a "length" and dimensions in the X-axis may be referred to as a "width." The electrode sub-units (e.g., 102) may be combined into one or more unit cells (e.g., Fig. 2). A cell can include (a) at least one anodically active material mass (e.g., layer, 104) and / or (b) at least one cathodically active material mass (e.g., layer, 106). In some embodiments, the anodically active material is separated from the cathode by the gap. In some embodiments, the cathodically active material is separated from the anode by the gap. In some embodiments, the cathodically active material is separated from the anodically active material by the gap. The set of cells may comprise at least 2, 10, 20, 50, 100, 150, 200, 250, or 500 cells. The set of cells may comprise any number of cells between any of the aforementioned number of cells, e.g., from 2 to 500 cells, or from 50 to 500 cells. An active material mass may operatively couple to a current collector. The active material mass may comprise one or more layers. The active material may form a gradient.

[0117] In some embodiments, the device includes an electrode busbar and a counter-electrode busbar. The electrode busbar can be operatively coupled with (e.g., electrically connected with) the electrode, e.g., via electrode tab. The counter-electrode busbar is operatively coupled with (e.g., electrically connected with) the counter-electrode, e.g., via counter-electrode tab. The electrode busbar can be operatively coupled with the electrodes of the set of cells, e.g., via electrode tabs. The counter-electrode busbar is operatively coupled with the counter-electrodes of the set of cells, e.g., via counter-electrode tabs. An electrode tab can be an extension of the electrode that is devoid of the electrode active material. A counter-electrode tab can be an extension of the counter-electrode that is devoid of the counter-electrode active material.Attorney Docket No. ENX-0160.WO

[0118] In example 100, the device (e.g., secondary battery) 100 include a first busbar 110 and a second busbar 112 that are in electrical contact with the anodes(s) (e.g., anodically active material layer 104) and the cathodes (e.g., cathodically active material layer 106) of each of the electrode sub-units 102, respectively, via electrode tabs 114. The electrode tabs 114 are only visible on a first side 120 of the secondary battery 100 in Fig. 1, although a different set of the electrode tabs 114 are present on a second side 121 of the secondary battery. The electrode tabs 114 on the first side 120 of the secondary battery 100 are electrically coupled with the first busbar 110, which may be referred to as an anode busbar. The electrode tabs 114 on the second side 121 of the secondary battery 100 (not visible in Fig. 1) are electrically coupled to the second busbar 112, which may be referred to as a cathode busbar. In this embodiment, the first busbar 110 is electrically coupled with a first electrical terminal 124 of the secondary battery 100, which is electrically conductive. When the first busbar 110 comprises an anode busbar for the secondary battery 100, the first electrical terminal 124 comprises a negative terminal for the secondary battery 100. Further in this embodiment, the second busbar 112 is electrically coupled with a second electrical terminal 125 of the secondary battery 100, which is electrically conductive. When the second busbar 112 comprises a cathode busbar for the secondary battery 100, the second electrical terminal 125 comprises a positive terminal for the secondary battery 100. In example 100, the secondary battery includes a first major surface 126 and a second major surface 127 that opposes the first major surface 126. The major surfaces 126, 127 of the secondary battery 100 may be substantially planar is some embodiments.

[0119] In one embodiment, a casing 116, which may be referred to as a constraint, may be applied over one or both of the X-Y surfaces of the secondary battery 100. In the embodiment shown in Fig. 1, the casing 116 includes a plurality of perforations 118 to facilitate distribution or flow of an electrolyte solution once the secondary battery 100 has been fully assembled. In one embodiment, the casing 116 comprises stainless steel, such as SS301, SS316, 440C or440C hard. In other embodiments, the casing 116 comprises aluminum (e.g., aluminum 7075-T6, hard H18, etc.), titanium (e.g., 6A1-4V), beryllium, beryllium copper (hard), copper (02 free, hard), nickel, other metals or metal alloys, composite, polymer, ceramic (e.g., alumina (e.g., sintered or Coorstek AD96), zirconia (e.g., Coorstek YZTP), yttria-stabilized zirconia (e.g., ENrG E-StrateO)), glass, tempered glass, polyetheretherketone (PEEK) (e.g., Aptiv 1102), PEEK with carbon (e.g., Victrex 90HMF40 orXycomp 1000-04), polyphenylene sulfide (PPS) with carbon (e.g., Tepex Dynalite 207), polyetheretherketone (PEEK) with 30% glass (e.g., Victrex 90HMF40 orXycomp 1000-04), polyimide (e.g., Kapton®), E Glass Std Fabric / Epoxy, 0 deg, E Glass UD / Epoxy, 0 deg, Kevlar Std Fabric / Epoxy, 0 deg, Kevlar UD / Epoxy, 0 deg, Carbon StdAttorney Docket No. ENX-0160.WOFabric / Epoxy, 0 deg, Carbon UD / Epoxy, 0 deg, Toyobo Zylon® HM Fiber / Epoxy, Kevlar 49 Aramid Fiber, S Glass Fibers, Carbon Fibers, Vectran UM LCP Fibers, Dyneema, Zylon, or other suitable material.

[0120] In some embodiments, the casing 116 comprises a sheet having a thickness in the range of about 10 to about 100 micrometers (pm). In one embodiment, the casing 116 comprises a stainless-steel sheet (e.g., SS316) having a thickness of about 30 pm. In another embodiment, the casing 116 comprises an aluminum sheet (e.g., 7075-T6) having a thickness of about 40 pm. In another embodiment, the casing 116 comprises a zirconia sheet (e.g., Coorstek YZTP) having a thickness of about 30 pm. In another embodiment, the casing 116 comprises an E Glass UD / Epoxy 0 deg sheet having a thickness of about 75 pm. In another embodiment, the casing 116 comprises 12 pm carbon fibers at >50% packing density.

[0121] In some embodiments, the cell may be coupled with a (e.g., solid) busbar. In some embodiments, the set of cells may be coupled with the (e.g., solid) busbar. The busbar may comprise a (e.g., solid) material of a class. The material class may include an elemental metal, a metal alloy, or an allotrope of elemental carbon, any plurality of types thereof, or any combination thereof. The busbar may comprise (e.g., solid) material, e.g., including one or more types of materials. At least two types of materials may belong to the same class of materials. At least two types of materials may belong to different classes of materials. A class of material may be a composite or a non-composite material. A class of material may be a tacky material (e.g., a tacky connector), or a solid material, e.g., that is non-tacky. A class of material may be a material that is fluid, or non-fluid, e.g., during manufacture of the energy manipulation device such as a battery. In an example, the (e.g., solid) busbar may comprise a metal alloy and an elemental metal. In an example, the (e.g., solid) busbar may comprise two types of metal alloys. In an example, the (e.g., solid) busbar may comprise a composite material and a non-composite material. The busbar may comprise any conductive material disclosed herein. In an example, the busbar includes copper (e.g., Cu101) and Inconel (e.g., N178). The material class can be an oxygen free material. The material class may be an electronic grade material.

[0122] In some embodiments, a busbar is attached to the current collector tabs, e.g., the attachment being assisted by the tacky connector. In an example, the busbar contacts the tacky connector that contacts the tab(s). The busbar may have a cross section of a Euclidean shape, e.g., a vertical cross section. The busbar may have a cross section of a geometric planar shape, e.g., a vertical cross section. The shape may include a polygon, an ellipse, a combination thereof and / or a plurality thereof. The polygon may include a rectangle, or a plurality of rectangles. In an example, a vertical cross section of the busbar is a rectangle. In an example,Attorney Docket No. ENX-0160.WOthe vertical cross section of the busbar comprises at least two different types of shapes, e.g., rectangles. In an example, the vertical cross section of the busbar comprises at least two types of shapes that are (e.g., substantially) the same, and that are distinct from each other. The two types of shapes may comprise the same type of material or may each be from a different type of material. The two types of shapes may comprise the same class of material or may each be from a different class of material. Two of the shapes may be separated from each other by a gap. Two of the shapes may contact each other. A cross section of the busbar may comprise an indentation, e.g., a depression. The depression may be configured to accommodate (a) folded tab(s) (b) any tacky connector, (c) any welding, or (d) any combination thereof. The depression may be configured to increase adhesion of the tab to the (e.g., solid) busbar. The increased adhesion may be at least in part by increasing the (e.g., solid) busbar’s adhesion to (i) any tacky connector and / or (ii) any welding. A contacting surface of the busbar is an exposed surface of the busbar face(s) configured to contract the (a) the tab(s), (b) any tacky connector, (c) any welding, or (d) any combination thereof. The contacting surface may undergo surface treatment before the contact. The surface treatment may be configured to increase adhesion between the (e.g., solid) busbar and (a) the tab(s), (b) any tacky connector, (c) any welding, or (d) any combination thereof. The surface treatment may comprise roughening of the contacting surface. The surface treatment may comprise etching, scraping, or printing (e.g., 3D printing). The surface treatment may comprise mechanical treatment type, chemical treatment type, any plurality thereof, or any combination thereof. The (e.g., solid) busbar may comprise one or more perforations (e.g., holes). The perforation(s) may be configured to accommodate dimensionality changes occurring in the cell, e.g., during charging and / or discharging. The dimensionality changes of the cell may occur during its (e.g., normal) operation, testing, maintenance, storage, shipping, or any combination thereof.

[0123] In some embodiments, the cell undergoes pre-loading with charge carriers, e.g., before its regular use. The pre-loading may comprise loading the cell with charge carriers, e.g., “pre-lithiation” in the case of lithium cations being the charge carriers. The pre-loading (also referred herein as “buffering”) may be performed during manufacturing and / or before providing the battery for its intended use. The pre-loading may facilitate insertion of additional charge carriers for a charge carrier source such as a lithium source, into the electrode(s) of the battery such as into the anode(s). The electrode may be a vertically short electrode. The pre-loading may replenish (e.g., irreversible) loss of the charge carriers during formation of the battery, e.g., to increase (a) efficiency of the first cycle and / or (b) cell capacity. The pre-loading may result in a reservoir of the charge carriers within the cell, and / or smaller cycled voltage window. The preAttorney Docket No. ENX-0160.WOloading may improve current distribution, e.g., during fast charge. The pre-loading may improve the cycle life of the battery. Buffering or pre-loading may result in pressurization of the cell at its first charging cycle, e.g., due to loading of the anode with charge carriers such as lithium. The pressure adjuster described herein can aid in maintaining overpressure in the system without having to put pressure during buffering, e.g., the adjuster can establish a minimal / threshold overpressure in the device during formation without having to buffer the cell. A rough exposed surface of charge carrier plating may remain throughout the life of the battery, and may compromise function of the battery, e.g., due to depletion of charge carriers and / or due to causing a short (e.g., as a consequence of dendrite formation from an electrode to its counter electrode). In some examples, the geometry of a battery may include a side gap located adjacent to a cell, to enable electrolyte to flow into the gap during buffering.

[0124] Fig. 2 depicts an example secondary battery 100 along cut lines D-D in Fig. 2, the individual layers of the unit cell 200, which may be the same as or similar to the electrode subunits 102, is shown. For each of the unit cells 200.

[0125] In some embodiments, a cell comprises an electrode (e.g., reference electrode), a counter electrode, separated from each other by a gap, also referred to herein as “a separation space.” The separation space may comprise a separator, e.g., having a material comprising conduits or pores, e.g., micro conduits, or micropores. The pores and / or conduits may be configured to facilitate charge carriers (e.g., ions) to propagate through the separator. The conduits may be channels. Pores of the separator may form the conduit. The battery cell may comprise, or may be coupled with, a nonconductor. The battery cell may comprise, or may be coupled with, a dividing space. At least one component may be electrically insulating, e.g., the separator body, the nonconductor, or at least one component of the dividing space. The dividing space and the separating space may or may not have the same material content. A divider material may be disposed in the dividing space. The dividing material may or may not be of the same type of material as the separator. The separator may be (e.g., substantially) a plane, or a layer. The separator may be an ionically permeable microporous material suitable for use as a separator in an electrochemical cell, e.g., as depicted in Fig. 1, 108. In some implementations, the microporous separator material includes pores having a diameter of at least about 50 Angstroms (A), for example of about 2,500 A, and a porosity in the range of at least about 25% to at most about 75%, for example, in the range of about 35% to 55%, inclusive. In some embodiments, the separator layer (e.g., 108) is coated with ceramic particles on one or both sides.Attorney Docket No. ENX-0160.WO

[0126] In some implementations, the separator layers 108 may each have a thickness of at least about 4pm. In some implementations, the separator layers 108 may have a thickness of at least about 8pm. In some implementations, the separator layers 108 may have a thickness of at least about 12 pm. In some implementations, the separator layers 108 may have a thickness of at least about 15 pm. In some implementations, the separator layers 108 may have a thickness of up to 25 pm, up to 50 pm, or any other suitable thickness. In some implementations, however, the separator layers 108 may have a thickness of less than about 12 pm or less than about 10 pm.

[0127] In some implementations, the material of the separator layers 108 may be selected from a wide range of material having the capacity to conduct carrier ions between the anodically active material layers 104 and the cathodically active material layers 106 of the unit cell 200. In some implementations, the separator layers 108 may comprise a microporous separator material that may be permeated with a liquid, non-aqueous electrolyte. Alternatively, the separator layers 108 may comprise a gel or solid electrolyte capable of conducting carrier ions between the anodically active material layers 104 and the cathodically active material layers 106 of the unit cell 200. In some implementations, the separator layers 108 may comprise an electrolyte. The electrolyte may be a polymer-based electrolyte. In some implementations, the separator layers 108 may comprise a solid-state lithium ion conducting ceramic, such as a lithium-stuffed garnet.

[0128] In one embodiment, the separator layers 108 comprise a microporous separator material. The microporous separator material may comprise a particulate material and / or a binder. The microporous separator material having a porosity (void fraction) of at least about 20 vol. %. The pores of the microporous separator material may have a diameter of at least 50 A and be within the range of at least about 250 A to at most about 2,500 A. The microporous separator material may typically have a porosity of less than about 75%. In some implementations, the microporous separator material has a porosity (void fraction) of at least about 25 vol %. In some implementations, the microporous separator material may have a porosity of at least about 35% to at most about 55%.

[0129] In some implementations, the binder for the microporous separator material may be selected from a wide range of inorganic or polymeric materials. In some implementations, the binder may be an organic material selected from the group consisting of silicates, phosphates, aluminates, aluminosilicates, and hydroxides such as magnesium hydroxide, calcium hydroxide, etc. In some implementations, the binder may be a fluoropolymer derived from monomers containing vinylidene fluoride, hexafluoropropylene, tetrafluoropropene, and the like. In someAttorney Docket No. ENX-016Q.WOimplementations, the binder is a polyolefin such as polyethylene, polypropylene, or polybutene, having any of a range of varying molecular weights and densities. In some implementations, the binder may be selected from the group consisting of ethylene-diene-propene terpolymer, polystyrene, polymethyl methacrylate, polyethylene glycol, polyvinyl acetate, polyvinyl butyral, polyacetal, and polyethyleneglycol diacrylate. In some implementations, the binder may be selected from the group consisting of methyl cellulose, carboxymethyl cellulose, styrene rubber, butadiene rubber, styrene-butadiene rubber, isoprene rubber, polyacrylamide, polyvinyl ether, polyacrylic acid, polymethacrylic acid, and polyethylene oxide. In some implementations, the binder may be selected from the group consisting of acrylates, styrenes, epoxies, and silicones. In some implementations, the binder may be a copolymer or blend of two or more of the aforementioned polymers.

[0130] In some embodiments, a cell (e.g., unit cell, 209) includes an anode current collector (e.g., 202) in the center, which may comprise or be electrically coupled with, one of the electrode tabs (e.g., 114) on one of the sides (e.g., 120, 821) of the secondary battery, e.g., as depicted in Fig. 1. In some implementations, the unit cell includes the anodically active material layer (e.g. ,104), the separator layer (e.g., 108), the cathodically active material layer (e.g., 106), and a cathode current collector (e.g., 204) in a stacked formation along a stacking axis. The cathode current collector (e.g., 204) may comprise a cathode tab devoid of cathode active material. The anode current collector may comprise an anode tab devoid of anode active material. The anode tab may be disposed at the same side of the cathode tab, or at a different side such as an opposing side. In some implementations, the cathode current collector 204 may comprise or be electrically coupled with, one of the electrode tabs 114 on one of the sides 120, 821 of the secondary battery 100 that is different than the anode current collector 202.

[0131] In some implementations, the placement of the cathodically active material layer 106 and the anodically active material layer 104 may be swapped, such that the cathodically active material layers are toward the center and the anodically active material layers are distal to the cathodically active material layers. In one embodiment, a unit cell 200A includes, from left to right in stacked succession, the anode current collector 202, the anodically active material layer 104, the separator layer 108, the cathodically active material layer 106, and the cathode current collector 204. In an alternative embodiment, a unit cell 200B includes, from left to right in stacked succession, the separator layer 108, a first layer of the cathodically active material layer 106, the cathode current collector 204, a second layer of the cathodically active material layer 106, the separator layer 108, a first layer of the anodically active material layer 104, the anodeAttorney Docket No. ENX-016Q.WOcurrent collector 202, a second layer of the anodically active material layer 104, and the separator layer 108.

[0132] Fig. 2 depicts a layered structure comprising the cathodically active material layer 106 and the cathode current collector 204 may be referred to as a cathode structure 206, while the layered structure comprising the anodically active material layer 104 and the anode current collector 202 may be referred to as an anode structure 207. Collectively, the population of the cathode structures 206 for the secondary battery 100 may be referred to as a positive electrode 908 of the secondary battery 100, and the population of the anode structures 207 for the secondary battery 100 (only one of the anode structures 207 are shown in Fig. 2) may be referred to as the negative electrode 209 of the secondary battery 100.

[0133] In some implementations, a voltage difference V exists between adjacent cathode structures 206 and anode structures 207, with the adjacent structures considered a bilayer in some embodiments. In various implementations, each bilayer may have a capacity C determined by the makeup and configuration of the cathode structures 206 and the anode structures 207. In some implementations, each bilayer produces a voltage difference of about 4.35 volts. In some implementations, each bilayer has a voltage difference of about 0.5 volts, about 1.0 volts, about 1.5 volts, about 2.0 volts, about 2.5 volts, about 3.0 volts, about 3.5 volts, about 4.0 volts, 4.5 volts, about 5.0 volts, between 4 and 5 volts, or any other suitable voltage. In some implementations, during cycling between a charged state and a discharged state, the voltage may vary, for example, between about 2.5 volts and about 4.35 volts. In some implementations, the capacity C of a bilayer in this embodiment is about 3.5 milliampere-hour (mAh). In some implementations, the capacity C of a bilayer is about 2 mAh, less than 5 mAh, or any other suitable capacity. In some implementations, the capacity C of a bilayer may be up to about 10 mAh.

[0134] In some embodiments, the cathode includes cathodically active material. The cathodically active material may include a cathodically active material including transition metal oxides, transition metal sulfides, transition metal nitrides, lithium-transition metal oxides, lithium-transition metal sulfides, lithium-transition metal nitrides, any plurality thereof, and / or any combination thereof. The cathodically active material may include transition metal elements of the transition metal oxides, transition metal sulfides, transition metal nitrides, any plurality thereof, and / or any combination thereof. The cathodically active material may include metal elements having a d-shell or f-shell. The cathodically active material may comprise metal element including Sc, Y, lanthanoids, actinoids, Ti, Zr, Hf, V, Nb, Ta, Cr, Mo, W, Mn, Tc, Re, Fe, Ru, Os, Co, Rh, Ir, Ni, Pb, Pt, Cu, Ag, Au, any plurality thereof, and / or any combination thereof.Attorney Docket No. ENX-016Q.WOThe cathodically active material may include lithium cobalt oxide (LiCoO2), LiNiosMni sC , Li(NixCoyAlz)C)2, lithium metal phosphate (e.g., lithium iron phosphate, LiFePCU), Li2MnC>4, V2O5, molybdenum oxysulfides, phosphates, silicates, vanadates, sulfur, sulfur compounds, oxygen (air), lithium nickel manganese cobalt oxide (Li(NixMnyCoz)O2), any combinations thereof, and / or any plurality thereof. In some implementations, the cathode (e.g., cathodically active material) is selected from transition metal oxides, transition metal sulfides, transition metal nitrides, lithium-transition metal oxides, lithium-transition metal sulfides, transition-metal phosphates, lithium-transition-metal phosphates, and lithium-transition metal nitrides may be selectively used. The transition metal elements of these transition metal oxides, transition metal sulfides, and transition metal nitrides can include metal elements having a d-shell or f-shell. Specific examples of such metal element are Sc, Y, lanthanides, actinides, Ti, Zr, Hf, V, Nb, Ta, Cr, Mo, W, Mn, Tc, Re, Fe, Ru, Os, Co, Rh, Ir, Ni, Pb, Pt, Cu, Ag, and Au. Additional cathode active materials include LiCoO2, LiNio5Mn15O4, Li(NixCoyAlz)O2, LiFePO4, Li2MnO4, V2O5, molybdenum oxysulfides, phosphates, silicates, vanadates, sulfur, sulfur compounds, oxygen (air), Li(NixMnyCoz)O2, and combinations thereof. The cathode active material may comprise, S (e.g., Li2S in the lithiated state), LiF, Fe, Cu, Ni, FeF2, FeOdF3.2d, FeFs, C0F3, CoF2, CuF2, NiF2, where 0<d<0.5, metal oxides, metal sulfides, metal phosphates, binders, fillers, any plurality thereof, or any combination thereof. The filler may be inert to the chemistry of the device, e.g., chemistry of the cell. The binders may include polyvinylidene difluoride and / or polytetrafluoroethylene. The cathode may comprise LCO, NCM, LFP, LMO, Nickel, Lithium manganese Iron phosphate, lithium manganese iron phosphate, sodium-ion, nickel, manganese rich lithium, lithiated cobalt oxide, lithiated manganese oxide, lithiated nickel-manganese-cobalt oxide, any plurality of types thereof, or any combination thereof. The cathode (e.g., and the device) may be devoid of cobalt. The cathode active material may comprise a dopant. The dopant may comprise at least one type of elemental metal. The at least one type of elemental metal may comprise aluminum, a transition metal, a rare earth metal, any plurality of types thereof, or any combination thereof. In some embodiments, the energy manipulation device may comprise a battery. The device may comprise Li-ion batteries, nickel metal hydride batteries, alkaline batteries, any plurality of types thereof, or any combination thereof. The battery may include a cell comprising Cu, Al, Ni, polyethylene, polypropylene, any derivatives thereof, any plurality of types thereof, or any combination thereof.

[0135] In some embodiments, the anode includes anodically active material. The anodically active material may include silicon (Si), germanium (Ge), tin (Sn), lead (Pb), antimony (Sb), bismuth (Bi), zinc (Zn), aluminum (Al), titanium (Ti), nickel (Ni), cobalt (Co), cadmium (Cd), anyAttorney Docket No. ENX-016Q.WOcombination thereof, and / or any plurality thereof. The anodically active material may include alloys and / or intermetallic compounds including Si, C, Ge, Sn, Pb, Sb, Bi, Zn, Al, Ti, Ni, Co, Cd, any combination thereof, and / or any plurality thereof. The anodically active material may include alloys, and / or intermetallic compounds. The anodically active material may include oxides, carbides, nitrides, sulfides, phosphides, selenides, tellurides of Si, Ge, Sn, Pb, Sb, Bi, Zn, Al, Ti, Fe, Ni, Co, V, or Cd, any combination thereof, or any plurality thereof. The anodically active material may include mixtures (e.g., containing Lithium), composites (e.g., containing Lithium), any combination thereof, and / or any plurality thereof. The anodically active material may include salts (e.g., of Sn), hydroxides (e.g., of Sn), lithium titanate, lithium manganate, lithium aluminate, lithium-containing titanium oxide, lithium transition metal oxide, ZnCo2C>4, particles of graphite, particles of carbon, metal form of the charge carriers (e.g., lithium metal), any combinations thereof, and / or any plurality thereof. The anodically active material may be coated. The coating may comprise stabilized metal form of the charge carrier material (e.g., lithium metal particles). The particulate material may include lithium carbonate-stabilized lithium metal powder, lithium silicate stabilized lithium metal powder, other source of stabilized lithium metal powder or ink, any combination thereof, and / or any plurality thereof. The anode active material may comprise a material intercalating the charge carriers. The active material of the anode may include silicon and / or an allotrope of elemental carbon. The allotrope of elemental carbon may be any of the ones disclosed herein, e.g., active carbon, graphite, carbon fiber, carbon nanotube, amorphous carbon, and / or a fullerene. The tubular structures may comprise nested tubes, e.g., at least 2, or 3 nested tubes. The carbon fibers may be weaved, aligned (e.g., in parallel and / or at an angle relative to each other), randomly situated, or any combination thereof, as applicable. The anode may be a nearly (e.g., substantially) 100% silicon - carbon anode. The anode may comprise particulate material. The anode may comprise a carbon scaffold on which silicon is deposited (e.g., layer of silicon). An exposed surface of the silicon may be coated by the, or by at least one other, of the allotropes of elemental carbon. The carbon may comprise black carbon. The carbon may include hard carbon and / or soft carbon. The carbon-silicon structure may comprise successive layers and / or scaffold. The carbon may comprise a particulate material. The particulate material may serve as a base for deposition of the one or more layers. The particulate material may or may not include crevices. The one or more layers may be deposited onto an exposed surface of the crevices. Anodically active materials may comprise carbon materials such as graphite and soft or hard carbons, or graphene (e.g., single-walled or multiwalled carbon nanotubes), or any of a range of metals, semi-metals, alloys, oxides, nitrides, compounds capable of intercalating lithium, compounds forming an alloy with lithium, anyAttorney Docket No. ENX-016Q.WOplurality thereof, or any combination thereof. Specific examples of the metals or semi-metals that may be used as the anode material include graphite, tin, lead, magnesium, aluminum, boron, gallium, silicon, Si-C composites, Si / graphite blends, silicon oxide (SiOx), porous Si, intermetallic Si alloys, indium, zirconium, germanium, bismuth, cadmium, antimony, silver, zinc, arsenic, hafnium, yttrium, lithium, sodium, graphite, carbon, lithium titanate, palladium, mixtures thereof, any plurality thereof, or any other combination thereof. In some implementations, the anodically active material may comprise aluminum, tin, silicon, an oxide thereof, a nitride thereof, a fluoride thereof, other alloy thereof, any plurality thereof, or any combination thereof. In some implementations, the anodically active material may comprise silicon, an alloy thereof, a composite thereof, an oxide thereof, any plurality thereof, or any combination thereof. In some embodiments, the battery may be without an active material (e.g., simple cell).

[0136] In some implementations, the particulate lithium material is applied on the anodically active material layers 104 by spraying, loading, and / or otherwise disposing the lithium particulate material onto the anodically active material layers 104 at a loading amount of about 0.05 mg / cm' to 5 mg / cm', e.g., about 0.1 mg / cm' to 4 mg / cm', or even about 0.5 mg / cm' to 3 mg / cm'. In some implementations, the average particle size (D50) of the lithium particulate material may be 5pm to 200 pm, e.g., about 10 pm to 100 pm, 20 pm to 80 pm, or even about 30 pm to 50 pm. In some implementations, the average particle size (D50) may be defined as a particle size corresponding to 50% in a cumulative volume-based particle size distribution curve. In some implementations, the average particle size (D50) may be measured, for example, using a laser diffraction method. The particulate material comprised by the microporous separator material may also be selected from a wide range of materials. In some implementations, such materials have a relatively low electronic and ionic conductivity at operating temperatures and do not corrode under the operating voltages of the battery electrode or current collector contacting the microporous separator material. In some implementations, the particulate material has a conductivity for carrier ions (e.g., lithium) of less than 1*10-4 Siemens / cm (S / cm). In some implementations, the particulate material may have a conductivity for carrier ions of less than 1*10-5 S / cm. In some implementations, the particulate material has a conductivity for carrier ions of less than 1*10-6 S / cm. In some implementations, particulate materials may include particulate polyethylene, polypropylene, a TiO2-polymer composite, silica aerogel, fumed silica, silica gel, silica hydrogel, silica xerogel, silica sol, colloidal silica, alumina, titania, magnesia, kaolin, talc, diatomaceous earth, calcium silicate, aluminum silicate, calcium carbonate, and / or magnesium carbonate. In some implementations, the particulate material may comprise a particulate oxide or nitride such as TiO2, SiO2, AI2O3, GeO2, B2O3, Bi2O3, BaO,Attorney Docket No. ENX-016Q.WOZnO, ZrO2, BN, Si3N4, and Ge3N4. In some implementations, the particulate material may have an average particle size from about 20 nm to 2pm, or from about 200 nm to about 1.5 pm. In some implementations, the particulate material may have an average particle size of about 500 nm to 1pm.

[0137] In some implementations, the particulate material comprised by the microporous separator material may be bound by techniques such as sintering, binding, curing, and / or a similar technique. The microporous separator material may be bound by a technique while maintaining the void fraction desired for electrolyte ingress to provide the ionic conductivity for the functioning of the battery.

[0138] In some embodiments, the electrode has an excess of active material binding sites for the charge carriers than the counter-electrode, e.g., molar excess. The excess in binding sites can be at least about 5%, 10%, 15%, or 20%. The excess in binding sites can be at most about 50%, 40%, 30%, 20%, or 10%. The excess in binding sites between the electrode and the counter electrode can be between any of the aforementioned values, e.g., from about 5% to about 50%, from about 5% to about 20%, or from about 15% to about 50%. The electrode can be an anode and the counter electrode - a cathode.

[0139] In some embodiments, the active material is compressed to form a densified active material cake coupled with a current collector, e.g., as part of the electrode and / or counter electrode. The density of the active material coupled with the current collector, may be at least about 0.5 grams per centimeter squared (g / cc), 0.8 g / cc, 1 g / cc, 2 g / cc 3 g / cc, 4 g / cc, 4.2 g / cc or 5 g / cc. The density of the active material coupled with the current collector, may be at most about 4.5 g / cc, 5 g / cc, 6 g / cc, or 8 g / cc. The density of the active material coupled with the current collector sheet, may be between any of the aforementioned values, e.g., from about 0.5 g / cc to about 8 g / cc, from about 0.5 g / cc to about 1 g / cc, or from about 2 g / cc to about 5 g / cc. In some embodiments, the density of the electrode active material is different from the density of the counter electrode active material, e.g., higher. The electrode can be a cathode, and the counter electrode an anode. In some embodiments, the density of the electrode active material is higher than the density of the counter electrode active material, e.g., by at least about 1.5*, 2*, 3*, 4*, or 5*, with the symbol designating the mathematical operation of multiplication. High densities or high press densities refer to electrode coatings compacted by a calendaring operation to a density of at least 4gr / cc, or above. The densification may be accomplished by using a heavy roller, e.g., weighing at least about 1 ton (T), 2T, 3T, or 4T. The calendaring may be pressure controlled or height controlled, e.g., using a controls system such as disclosed herein. The calendering may be achieved, e.g., through a height-controlled operation. TheAttorney Docket No. ENX-0160.WOheight-controlled operation may set a fixed gap between the rollers, or between a roller and a surface, e.g., a gap of at most about 20 micrometers (pm), 40 pm, 60 pm, 80 pm, or 100 pm, such as to define the active material thickness.

[0140] In some embodiments, the energy manipulation device comprises an electrochemical cell. The cell may comprise an electrode and a counter-electrode separated from each other by a gap. The device may comprise a simple cell, e.g., comprising passive electrodes. The simple cell may comprise anode current collector, cathode current collector separated from the anode current collector by a gap, an electrolyte, and charge carriers. The cell may comprise partially active electrodes - one current collector contacting an active material mass. The mass can be a layer. The cell may comprise fully active electrodes - both electrode and counter-electrode current collectors of the cell, each contacting a respective active material mass, e.g., a layer.

[0141] In some examples, the energy manipulation device may comprise a fuel cell. In other examples, the energy manipulation device may comprise a primary battery, which may be a non-rechargeable battery. The primary battery may be a battery comprising Li metal, alkaline, zinc-carbon, silver-oxide, and / or any other suitable material. In some examples, the energy manipulation device may comprise a secondary battery, which may be rechargeable. The secondary battery may be a battery comprising Li ion, lead acid (lead dioxide with sulfuric acid), nickel cadmium, nickel metal hydride, and / or any other suitable material. The use of a secondary battery or rechargeable battery may enable a reduction in environmental waste, as the materials may be reused for multiple cycles as compared to a primary or non-rechargeable battery. In some examples, the energy manipulation device described herein may comprise an electrochemical cell. As noted above, the cell may include an anode material and a cathode material. In an example, an electrochemical cell comprises passive electrodes, wherein the simple electrochemical cell includes an anode charge carrier, a cathode charge carrier separated from the anode by a gap, an electrolyte and charge carriers. In some examples, the energy manipulation device may comprise one or more active electrodes, wherein one charge carrier is in contact with an active material mass. The active material mass can comprise (e.g., be deposited in a form of) a layer. In some examples, the energy manipulation device may comprise one or more fully active electrodes, wherein the electrode and / or counter electrode charge carriers of a cell each contact a respective active material mass, e.g., a layer. The active material mass is configured to operatively coupled with its respective current collector of the electrode. The current collector may have an electrical conductivity of at least about 103Siemens / cm (S / cm), 104S / cm, 105S / cm, or 106S / cm. The current collector may have anAttorney Docket No. ENX-016Q.WOelectrical conductivity between any of the aforementioned values, e.g., from about 103S / cm to about 106S / cm, or from about 105S / cm to about 106S / cm.

[0142] In some examples, the cell comprises an active material, a charge carrier, an electrolyte, any plurality of types thereof, or any combination thereof. The active material (e.g., mass such as layer) may be added to one side or to both sides of a cell or cell stack. In some embodiments, the electrode comprises a current collector (e.g., conductor) comprising elemental metal, metal alloys, an allotrope of elemental carbon, any plurality of types thereof, or any combination thereof. The allotrope of elemental metal may comprise graphite, carbon nanotubes, carbon wires, fullerenes, hard carbon, soft carbon, active carbon, carbon black, acetylene black, Ketjen black, cylindrical carbon nanotubes, carbon fibers, any plurality of types thereof, or any combination thereof. The nanotubes and / or nanowires, may be nested or nonnested. The cell may comprise charge carriers comprising salts such as lithium salts. The electrolyte material may comprise solid, semi-solid, liquid, any plurality of types thereof, or any combination thereof. The electrolyte materials may include salts, acids, and / or bases, e.g., dissolved in non-aqueous polar solvent(s). In some implementations, the non-aqueous electrolyte comprises a lithium salt and / or mixture of salts dissolved in an organic solvent and / or solvent mixture. In some implementations, the lithium salts may include inorganic lithium salts such as LiCIO4, LiBF4, LiPF6, LiAsF6, LiCI, and / or LiBr; and organic lithium salts such as LiB(C6H5)4, LiN(SO2CF3)2, LiN(SO2CF3)3, LiNSO2CF3, LiNSO2CF5, LiNSO2C4F9, LiNSO2C5F11, LiNSO2C6F13, and / or LiNSO2C7F15. In some implementations, the organic solvents to dissolve the lithium salt may include cyclic esters, chain esters, cyclic ethers, and / or chain ethers. In some implementations, the cyclic esters may include propylene carbonate, butylene carbonate, y-butyrolactone, vinylene carbonate, 2-methyl-y-butyrolactone, acetyl-y-butyrolactone, and / or y-valerolactone. In some implementations, the chain esters may include dimethyl carbonate, diethyl carbonate, dibutyl carbonate, dipropyl carbonate, methyl ethyl carbonate, methyl butyl carbonate, methyl propyl carbonate, ethyl butyl carbonate, ethyl propyl carbonate, butyl propyl carbonate, alkyl propionates, dialkyl malonates, and / or alkyl acetates. In some implementations, the cyclic ethers may include tetrahydrofuran, alkyltetrahydrofurans, dialkyltetrahydrofurans, alkoxytetrahydrofurans, dialkoxytetrahydrofurans, 1 ,3-dioxolane, alkyl-1,3-dioxolanes, and / or 1,4-dioxolane. In some implementations, the chain ethers may include 1,2-dimethoxyethane, 1,2-diethoxythane, diethyl ether, ethylene glycol dialkyl ethers, diethylene glycol dialkyl ethers, triethylene glycol dialkyl ethers, and / or tetraethylene glycol dialkyl ethers. In some embodiments, the electrolyte may comprise a polymer-based electrolyte. The polymer-based electrolyte may include PEO-based polymer electrolyte, polymer-ceramic compositeAttorney Docket No. ENX-0160.WOelectrolyte, polymer-ceramic composite electrolyte, polymer-ceramic composite electrolyte, and / or similar such electrolytes. In some embodiments, the electrolyte may include an oxidebased electrolyte (e.g., lanthanum titanate (Lio.34Lao.56TiO3), Al-doped lithium lanthanum zirconate (Li6.24La3ZrzAlo.24011.98), Ta-doped lithium lanthanum zirconate (Li6.4La3Zri.4Tao.6012), lithium aluminum titanium phosphate (Lit.4Alo.4Tit.6(PO4)3), and / or similar such electrolytes. In some embodiments, the electrolyte may comprise a solid electrolyte (e.g., sulfide-based electrolyte such as lithium tin phosphorus sulfide (LiioSnP2Si2), lithium phosphorus sulfide (13-U3PS4), lithium phosphorus sulfur chloride iodide (Li6PS5C1o.91o.i), and / or similar such electrolytes. The electrolyte may comprise ethylene carbonate, diethylcarbonate, dimethylcarbonate, ethylmethylcarbonate, propylene carbonate, any derivatives thereof, or any combination thereof.

[0143] Fig. 26 shows in example 26002600 a schematic representation of a cell, the cell comprising an electrode 2602a - “C” (e.g., a cathode), and an opposing electrode which is a counter electrode 2605a - “A” (e.g., an anode). A separator is disposed in separator space (e.g., gap) 2603 - “B.” The battery cell is disposed in a battery having housing 2609. The housing can be rigid, or flexible. The housing may include a rigid portion and / or a flexible portion. The battery can optionally have a nonconductor 2604. The nonconductor may comprise one or more materials comprising a ceramic, a polymer, or a resin. The battery may comprise one or more nonconductor types. In an example, a polymer may fill a cathode gap, and alumina fills a cathode gap, the gap being from the edge of the cell to its immediately adjacent edge of the case (also herein “casing”). In some embodiments, nonconductor may comprise a non-electrically conductive material. The ceramic may comprise alumina (AI2O3), zirconia (ZnC>2), magnesium oxide (MgO), boron nitride (BN), mullite, boehmite, or silicon carbide (SiC, e.g., in pure form). Under normal conditions during use of the battery, the main current is a load current 2606 passing from one electrode to its opposing electrode, and through separation space 2603. When volume 2604 comprises the nonconductor, the nonconductor contacts at least at opposing sides 2602b and 2602c of electrode 2602a and at opposing sides 2605b and 2605c of counter-electrode 2605a.

[0144] Fig. 26 shows in example 2610 a schematic representation of a cell, the cell comprising an electrode 2612 - “C” (e.g., a cathode), and an opposing electrode which is a counter electrode 2615 - “A” (e.g., an anode). A separator is disposed in separator space 2613 - “B.” The battery cell is disposed in a battery having housing 2619. The separation space extends 2712621 beyond electrode 2612, and extends 2622 beyond counter electrode 2615, the extension being along a long axis of each of the electrode, the long axis depicted in Fig. 26. TheAttorney Docket No. ENX-016Q.WOextension can extend longer in the lateral direction. The extension can form the tab. The battery has a nonconductor 2614. Under the normal conditions, the load current 2616 may be passing through separation space 2613.

[0145] In some embodiments, the different extension distances of the components of the cell in the lateral direction, form a corrugated (e.g., misaligned) face of the cell, and thus a set of the cells, e.g., as depicted in Fig. 26, 2702620 for a cell. The cell can comprise at least one uneven side, e.g., as is depicted in Fig. 26, 2702620. The uneven (e.g., misaligned) side can create a wavy side of a set of cells.

[0146] Fig. 27 shows a schematic example 2700 of a current collector in the form of a film or strip. The electrode active material may contact (e.g., be deposited onto) a conductive sheet, e.g., having a thickness of at most about 6 millimeters (mm), 5mm, 2.5mm, 1 mm, or 0.5mm. The conductive sheet may be a foil, e.g., having a thickness of at most about 0.4mm, 0.2 mm, or 0.1mm. The current collector may comprise an internal portion, e.g., when assembled in the battery. The internal portion of the current collector contacts the active material of the electrode. The tab may be (e.g., substantially) devoid of the electrode active material. The current collector has a length axis and a width, and a height. The current collector has a face type having a largest surface area, the face type including sections 2701, and 2702. The current collector has a length 2703, a width 2704, and a height 2705. Section 2702 designates the tab of the current collector that can bend upon assembly of the energy manipulation device such as to couple with a busbar, and section 2701 designates the planar section of the current collector that can couple to an electrode active material, e.g., a powder with binder(s) and / or filler(s). In the example shown in 2700, the tabs assume the same width 2704 along their length. In some embodiments, the tabs contract (e.g., narrow such as taper) along their length, e.g., and along the longest axis 2711. Longest axis 2711 of the current collector intersects position 2714 on a face of the electrode having height 2705 and width 2704, which face has the smallest surface area in the example of 2700. The current collector has a shorter axis 2712 normal to axis 2711. The contraction of the tabs along axis 2711 may be symmetrical about axis 2711, e.g., using a mirror symmetry, the mirror being along axis 2711.

[0147] In some embodiments, the current collector may be an anode current collector (e.g., Fig.2, 202). In some embodiments, the current collector may be a cathode current collector (e.g., Fig. 2, 204). The anode current collector (e.g., 202) may comprise a conductive material such as copper, carbon, nickel, stainless-steel, cobalt, titanium, and tungsten, and alloys thereof, or any other material suitable as an anode current collector layer. The current collector (e.g., 202, 204) has an electrical conductivity of at least about 103 Siemens / cm, 104 Siemens / cm, or 105Attorney Docket No. ENX-016Q.WOSiemens / cm. The current collector (e.g., 202, 204) has an electrical conductivity between any of the aforementioned values, e.g., from about 103 Siemens / cm to about 105 Siemens / cm. The cathode current collector may comprise aluminum, nickel, cobalt, titanium, and tungsten, or alloys thereof, or any other material suitable for use as a cathode current collector layer. In some embodiments, the cathode current collector comprises a metal such as aluminum, carbon, chromium, gold, nickel, NiP, palladium, platinum, rhodium, ruthenium, an alloy of silicon and nickel, titanium, or a combination thereof. In an example, a cathode current collector (e.g., Fig.2, 204) comprises gold or an alloy thereof such as gold silicide. By way of further example, in one embodiment, a cathode current collector (e.g., Fig. 2, 204) comprises nickel or an alloy thereof such as nickel silicide. In some implementations, the cathodically active material layer 106 may be an intercalation-type chemistry active material, a conversion chemistry active material, or a combination thereof.

[0148] In some implementations, the anode current collector 202, has an electrical conductance that is substantially greater than the electrical conductance of its associated anodically active material layers 104. In some implementations, in one embodiment, the ratio of the electrical conductance of the anode current collector 202 to the electrical conductance of the anodically active material layers 104 is at least 100:1 when there is an applied current to store energy in the secondary battery 100 or an applied load to discharge the secondary battery 100. In some implementations, the ratio of the electrical conductance of the anode current collector 202 to the electrical conductance of the anodically active material layers 104 is at least 500:1 when there is an applied current to store energy in the secondary battery 100 or an applied load to discharge the secondary battery 100. In some implementations, the ratio of the electrical conductance of the anode current collector 202 to the electrical conductance of the anodically active material layers 104 is at least 1000:1 when there is an applied current to store energy in the secondary battery 100 or an applied load to discharge the secondary battery 100. In some implementations, the ratio of the electrical conductance of the anode current collector 202 to the electrical conductance of the anodically active material layers 104 is at least 5000:1 when there is an applied current to store energy in the secondary battery 100 or an applied load to discharge the secondary battery 100. In some implementations, the ratio of the electrical conductance of the anode current collector 202 to the electrical conductance of the anodically active material layers 104 is at least 10,000:1 when there is an applied current to store energy in the secondary battery 100 or an applied load to discharge the secondary battery 100.

[0149] In some implementations, the cathodically active material layers 106 may have a thickness of at least about 20 pm. For example, in one embodiment, the cathodically activeAttorney Docket No. ENX-0160.WOmaterial layers 106 may have a thickness of at least about 40 pm. In some implementations, the cathodically active material layers 106 may have a thickness of at least about 60 pm. In some implementations, the cathodically active material layers 106 may have a thickness of at least about 100 pm. In some implementations, the cathodically active material layers 106 have a thickness of less than about 90 pm or less than about 70 pm.

[0150] Fig. 3 depicts an example of one of the cathode structures 206 of Fig. 2. Each cathode structure 206 has a length (LCE) measured along the longitudinal axis (ACE), a width (WCE), and a height (HCE) measured in a direction that is perpendicular to each of the directions of measurement of the length LCE and the width WCE.

[0151] In some implementations, the length LCE of the cathode structures 106 may vary depending upon the secondary battery 100 and its intended use. In some implementations, however, each cathode structure 206 may typically have a length LCE in the range of about 5 millimeters (mm) to about 500 mm. In some implementations, each cathode structure 206 has a length LCE of about 10 mm to about 250 mm. In some implementations, in one such embodiment each cathode structure 206 has a length LCE of about 25 mm to about 100 mm. In some implementations, the cathode structures 206 include one or more first electrode members having a first length, and one or more second electrode members having a second length that is different than the first length. In some implementations, the different lengths for the one or more first electrode members and one or more second electrode members may be selected to accommodate a predetermined shape for an electrode assembly, such as an electrode assembly shape having different lengths along one or more of the longitudinal and / or transverse axis, and / or to provide predetermined performance characteristics for the secondary battery 200.

[0152] In some implementations, the width WCE of the cathode structures 206 may also vary depending upon the secondary battery 100 and its intended use. In some implementations, however, the cathode structures 206 may typically have a width WCE within the range of about 0.01 mm to 2.5 mm. In some implementations, the width WCE of each cathode structure 206 may be in the range of about 0.025 mm to about 2 mm. In some implementations, in one embodiment, the width WCE of each cathode structure 206 may be in the range of about 0.05 mm to about 1 mm. In some implementations, the cathode structures 206 include one or more first electrode members having a first width, and one or more second electrode members having a second width that is different than the first width. In some implementations, the different widths for the one or more first electrode members and one or more second electrode members may be selected to accommodate a predetermined shape for the secondary battery 100, such as anAttorney Docket No. ENX-0160.WOassembly having different widths along one or more of the longitudinal and / or transverse axis, and / or to provide predetermined performance characteristics for the secondary battery 100.

[0153] In some implementations, the height HCE of the cathode structures 206 may also vary depending upon the secondary battery 100 and its intended use. In some implementations, however, the cathode structures 206 may typically have a height HCE within the range of about 0.05 mm to about 25 mm. In some implementations, the height HCEOf each cathode structure 206 may be in the range of about 0.05 mm to about 5 mm. In some implementations, in one embodiment, the height HCE of each cathode structure 206 may be in the range of about 0.1 mm to about 1 mm. In some implementations, the cathode structures 206 include one or more first cathode members having a first height, and one or more second cathode members having a second height that is different than the first height. In some implementations, the different heights for the one or more first cathode members and one or more second cathode members may be selected to accommodate a predetermined shape for the secondary battery 100, such as a shape having different heights along one or more of the longitudinal and / or transverse axis, and / or to provide predetermined performance characteristics for the secondary battery 100.

[0154] In some implementations, each cathode structure 206 has a length LCE that is substantially greater than its width WCE and substantially greater than its height HCE. In some implementations, the ratio of LCE to each of WCE and HCE is at least 5: 1 , respectively (that is, the ratio of LCE to WCE is at least 5: 1 , respectively and the ratio of LCE to HCE is at least 5: 1 , respectively), for each cathode structure 206. In some implementations, in one embodiment the ratio of LCE to each of WCE and HCE is at least 10:1 for each cathode structure 206. In some implementations, in one embodiment, the ratio of LCE to each of WCE and HCE is at least 15:1 for each cathode structure 206. In some implementations, in one embodiment, the ratio of LCE to each of WCE and HCE is at least 20: 1 for each cathode structure 206.

[0155] In some implementations, the ratio of the height HCE to the width WCE of the cathode structures 206 is at least 0.4:1, respectively. In some implementations, the ratio of HCEto WCE may be at least 2:1, respectively, for each cathode structure 206. In some implementations, in one embodiment, the ratio of HCE to WCE may be at least 10:1, respectively, for each cathode structure 206. In some implementations, in one embodiment, the ratio of HCE to WCE may be at least 20:1 , respectively, for each cathode structure 206. Typically, however, the ratio of HCE to WCE may generally be less than 1 ,000:1 , respectively, for each cathode structure 206. In some implementations, the ratio of HCEto WCE may be less than 500:1, respectively, for each cathode structure 206. In some implementations, in one embodiment, the ratio of HCE to WCE may be less than 100:1, respectively. In some implementations, in one embodiment, the ratio of HCE toAttorney Docket No. ENX-0160.WOWCE may be less than 10:1, respectively. In some implementations, in one embodiment, the ratio of HcEto WCE may be in the range of about 2:1 to about 100:1, respectively, for each cathode structure 206.

[0156] In some implementations, the anodically active material layers 104 are microstructured to provide a significant void volume fraction to accommodate volume expansion and contraction as lithium ions (or other carrier ions) are incorporated into or leave the anodically active material layers 104 during charging and discharging processes for the secondary battery 100. In some implementations, the void volume fraction of (each of) the anodically active material layer 104 is at least 0.1. In some implementations, however, the void volume fraction of (each of) the anodically active material layer 104 is not greater than 0.8. In some implementations, the void volume fraction of (each of) the anodically active material layer 104 is about 0.15 to about 0.75. In some implementations, the void volume fraction of (each of) the anodically active material layer 104 is about 0.2 to about 0.7. In some implementations, the void volume fraction of (each of) the anodically active material layer 104 is about 0.25 to about 0.6.

[0157] Depending upon the composition of the microstructured anodically active material layers 104 and the method of their formation, the microstructured anodically active material layers 104 may comprise macroporous, microporous, or mesoporous material layers or a combination thereof, such as a combination of microporous and mesoporous, or a combination of mesoporous and macroporous. Microporous material is typically characterized by a pore dimension of less than 10 nanometer (nm), a wall dimension of less than 10 nm, a pore depth of 1 m to 50 pm, and a pore morphology that is generally characterized by a "spongy" and irregular appearance, walls that are not smooth, and branched pores. Mesoporous material is typically characterized by a pore dimension of 10 nm to 50 nm, a wall dimension of 10 nm to 50 nm, a pore depth of 1 pm to 100 pm, and a pore morphology that is generally characterized by branched pores that are somewhat well defined or dendritic pores. Macroporous material is typically characterized by a pore dimension of greater than 50 nm, a wall dimension of greater than 50 nm, a pore depth of 1pm to 500 pm, and a pore morphology that may be varied, straight, branched, or dendritic, and smooth or rough-walled. Additionally, the void volume may comprise open or closed voids, or a combination thereof. In some implementations, the void volume comprises open voids, that is, the anodically active material layers 104 contain voids having openings at the lateral surface of the anodically active material layers through which lithium ions (or other carrier ions) can enter or leave. In some implementations, lithium ions may enter the anodically active material layers 104 through the void openings after leaving the cathodically active material layers 106. In some implementations, the void volume comprisesAttorney Docket No. ENX-0160.WOclosed voids, that is, the anodically active material layers 104 contain voids that are enclosed. In some implementations, open voids can provide greater interfacial surface area for the carrier ions whereas closed voids tend to be less susceptible to SEI formation, while each provides room for the expansion of anodically active material layers 104 upon the entry of carrier ions. In certain embodiments, therefore, it is preferred that the anodically active material layers 104 comprise a combination of open and closed voids.

[0158] In some implementations, the anodically active material layers 104 comprise porous aluminum, tin or silicon or an alloy, an oxide, or a nitride thereof. Porous silicon layers may be formed, for example, by anodization, by etching (e.g., by depositing precious metals such as gold, platinum, silver or gold / palladium on the surface of single crystal silicon and etching the surface with a mixture of hydrofluoric acid and hydrogen peroxide), or by other methods known in the art such as patterned chemical etching. Additionally, the porous anodically active material layers 104 may generally have a porosity fraction of at least about 0.1, but less than 0.8 and have a thickness of about 1 m to about 100 pm. In some implementations, the anodically active material layers 104 comprise porous silicon, have a thickness of about 5pm to about 100 pm, and have a porosity fraction of about 0.15 to about 0.75. In some implementations, the anodically active material layers 104 comprise porous silicon, have a thickness of about 10 pm to about 80 pm, and have a porosity fraction of about 0.15 to about 0.7. In some implementations, the anodically active material layers 104 comprise porous silicon, have a thickness of about 20 pm to about 50 pm, and have a porosity fraction of about 0.25 to about 0.6. In some implementations, the anodically active material layers 104 comprise a porous silicon alloy (such as nickel silicide), have a thickness of about 5pm to about 100 pm, and have a porosity fraction of about 0.15 to about 0.75.

[0159] In some implementations, the anodically active material layers 104 comprise fibers of aluminum, tin, or silicon, or an alloy thereof. Individual fibers may have a diameter (thickness dimension) of about 5 nm to about 10,000 nm and a length generally corresponding to the thickness of the anodically active material layers 104. Fibers (nanowires) of silicon may be formed, for example, by chemical vapor deposition or other techniques known in the art such as vapor liquid solid (VLS) growth and solid liquid solid (SLS) growth. Additionally, the anodically active material layers 104 may generally have a porosity fraction of at least about 0.1, but less than 0.8 and have a thickness of about 1 pm to about 200 pm. In some implementations, the anodically active material layers 104 comprise silicon nanowires, have a thickness of about 5pm to about 100 pm, and a porosity fraction of about 0.15 to about 0.75. In some implementations, the anodically active material layers 104 comprise silicon nanowires, have a thickness of aboutAttorney Docket No. ENX-016Q.WO10 pm to about 80 pm, and a porosity fraction of about 0.15 to about 0.7. In some implementations, the anodically active material layers 104 comprise silicon nanowires, have a thickness of about 20 pm to about 50 pm, and a porosity fraction of about 0.25 to about 0.6. In some implementations, the anodically active material layers 104 comprise nanowires of a silicon alloy (such as nickel silicide), have a thickness of about 5pm to about 100 pm, and a porosity fraction of about 0.15 to about 0.75.

[0160] Fig. 4 depicts one of the anode structures 207 of Fig. 2 of an example embodiment. Each anode structure 207 has a length (l_E) measured along a longitudinal axis (AE) of the electrode, a width (WE), and a height (HE) measured in a direction that is orthogonal to each of the directions of measurement of the length l_Eand the width WE.

[0161] The length l_Eof the anode structures 207 may vary depending upon the secondary battery 100 and its intended use. In general, however, the anode structures 207 may typically have a length LEin the range of about 5 millimeter (mm) to about 500 mm. For example, in one such embodiment, the anode structures 207 have a length LEof about 10 mm to about 250 mm. By way of further example, in one such embodiment, the anode structures 207 have a length LEof about 25 mm to about 100 mm. According to one embodiment, the anode structure 207 include one or more first electrode members having a first length, and one or more second electrode members having a second length that is different than the first length. In yet another embodiment, the different lengths for the one or more first electrode members and the one or more second electrode members may be selected to accommodate a predetermined shape for the secondary battery 100, such as a shape having different lengths along one or more of the longitudinal and / or transverse axis, and / or to provide predetermined performance characteristics for the secondary battery 100.

[0162] The width WEof the anode structures 207 may also vary depending upon the secondary battery 100 and its intended use. In general, however, each anode structure 207 may typically have a width WEwithin the range of about 0.01 mm to 2.5 mm. For example, in one embodiment, the width WEof each anode structure 207 may be in the range of about 0.025 mm to about 2 mm. By way of further example, in one embodiment, the width WEof each anode structure 207 may be in the range of about 0.05 mm to about 1 mm. According to one embodiment, the anode structures 207 include one or more first electrode members having a first width, and one or more second electrode members having a second width that is different than the first width. In yet another embodiment, the different widths for the one or more first electrode members and one or more second electrode members may be selected to accommodate a predetermined shape for the secondary battery 100, such as a shape havingAttorney Docket No. ENX-0160.WOdifferent widths along one or more of the longitudinal and / or transverse axis, and / or to provide predetermined performance characteristics for the secondary battery 100.

[0163] The height HE of the anode structures 207 may also vary depending upon the secondary battery 100 and its intended use. In general, however, the anode structures 207 may typically have a height HEwithin the range of about 0.05 mm to about 25 mm. For example, in one embodiment, the height HEof each anode structure 207 may be in the range of about 0.05 mm to about 5 mm. By way of further example, in one embodiment, the height HEof each anode structure 207 may be in the range of about 0.1 mm to about 1 mm. According to one embodiment, the anode structures 207 include one or more first electrode members having a first height, and one or more second electrode members having a second height that is different than the first height. In yet another embodiment, the different heights for the one or more first electrode members and one or more second electrode members may be selected to accommodate a predetermined shape for the secondary battery 100, such as a shape having different heights along one or more of the longitudinal and / or transverse axis, and / or to provide predetermined performance characteristics for the secondary battery 100.

[0164] In general, the anode structures 207 each have a length LEthat is substantially greater than each of its width WEand its height HE. For example, in one embodiment, the ratio of LEto each of WEand HEis at least 5:1, respectively (that is, the ratio of LEto WEis at least 5:1, respectively and the ratio of LEto HEis at least 5:1 , respectively), for each anode structure 207. By way of further example, in one embodiment, the ratio of LEto each of WEand HEis at least 10:1. By way of further example, in one embodiment, the ratio of l_Eto each of WEand HEis at least 15:1. By way of further example, in one embodiment, the ratio of l_Eto each of WEand HEis at least 20:1, for each anode structure 207.

[0165] In one embodiment, the ratio of the height HEto the width WEof the anode structures 207 is at least 0.4:1 , respectively. For example, in one embodiment, the ratio of HEto WEmay be at least 2:1 , respectively, for each anode structure 207. By way of further example, in one embodiment, the ratio of HEto WEmay be at least 10:1, respectively. Byway of further example, in one embodiment, the ratio of HEto WEmay be at least 20:1, respectively. Typically, however, the ratio of HEto WEmay generally be less than 1,000:1, respectively. For example, in one embodiment, the ratio of HEto WEmay be less than 500:1, respectively. By way of further example, in one embodiment, the ratio of HEto WEmay be less than 100:1, respectively. By way of further example, in one embodiment, the ratio of HEto WEmay be less than 10:1 , respectively. By way of further example, in one embodiment, the ratio of HEto WEmay be in the range of about 2:1 to about 100:1, respectively, for each anode structure 207.Attorney Docket No. ENX-0160.WO

[0166] Fig. 27 shows in example 2750, a schematic vertical cross section of various batteries, showing arrangement and / or folding of battery cells with respect to a Cartesian coordinate system. In example 2751, battery cells are arranged parallel to each other. Examples 2752-2755 show various folding of a sheet comprising one or more battery cells, with 2752 showing a zigzag fold, 2753 showing a top hat fold, 2754 showing a sinusoidal type fold, 2755 showing a spiral (e.g., rolling) fold, and 2756 an oval or oblong spiral (e.g., rolling) fold. The battery may comprise a battery cell folded in a wound (e.g., jelly roll) configuration having an oblong or cylindrical configuration, e.g., as shown in Fig. 32, 3250.

[0167] In some embodiments, one or more cells are disposed within a housing to form the device, e.g., battery. The housing may insulate the battery from one or more reactive agents (also referred to herein as “reactive species”) in the ambient environment external to the device. The reactive agent(s) may comprise oxygen, water, alcohol, thiol, sulfuric acid, phosphoric acid, carboxylic acid, hydrogen sulfide, any plurality thereof, or any combination thereof. The reactive agent(s) may be oxygen based, sulfur based, and / or phosphorous based. The reactive agent(s) may include water and / or oxygen. In an example, the reactive agent(s) comprise water in a liquid and / or vapor form. The water may be in the form of droplets. The housing may be configured to separate and / or insulate the cell(s) from the reactive agent(s) present in the ambient environment external to the device, e.g., to curtail (e.g., hinder, or prevent) reactive agent(s) from reaching the cell such as including reaching the electrode(s) and any fuse of the device.

[0168] The energy manipulation device (e.g., battery) is of a (e.g., Euclidean) three-dimensional (3D) geometric shape. The device may have an asymmetrical shape, e.g., its housing may be asymmetrical in shape. The Euclidean 3D shape may comprise a cylinder or a prism. The prism may be a Euclidean prism, or an amorphous prism. In some embodiments, the battery is a prismatic battery. In some embodiments, the battery is a cylindrical battery. The battery may have a first FLS such as a height (e.g., Fig. 28, 2831) of at least about 1 millimeters (mm), 2 mm, 3 mm, 5 mm, 6 mm, 8 mm, or 10 mm. The first FLS of the battery may be of any value between any of the aforementioned values, e.g., from about 1mm to about 10mm. The battery may have a second FLS such as a length (e.g., Fig. 28, 2832) of at least about at least about 10 millimeters (mm), 50 mm, 100 mm, 150 mm, or 200 mm. The second FLS of the battery may be of any value between any of the aforementioned values, e.g., from about 10mm to about 200mm. The battery may have an aspect ratio of the second FLS to the first FLS of at least about 2:1, 3.5:1 5:1, 8:1, 10:1, 15:1, 20:1, 25:1, 35:1, or 50:1. The battery may have an aspect ratio of the second FLS to the first FLS between any of the aforementioned values, e.g., fromAttorney Docket No. ENX-016Q.WOabout 5:1 to about 50:1, or from 2:1 to 50:1. The battery may have a third FLS such as a width (e g., Fig. 28, 2833) of at least about at least about 10 millimeters (mm), 30 mm, 50 mm, 100 mm, 150 mm, or 200 mm. The third FLS of the battery may be of any value between any of the aforementioned values, e.g., from about 10 mm to about 200 mm. The battery may have an aspect ratio of the third FLS to the first FLS of at least about 2:1, 3.5:1 5:1, 8:1, 10:1, 15:1, 20:1, 25: 1 , 35: 1 , 50: 1 , 75: 1 , or 100: 1. The battery may have an aspect ratio of the third FLS to the first FLS between any of the aforementioned values, e.g., from about 5:1 to about 50:1, or from 2:1 to 100:1.

[0169] In some embodiments, the energy manipulation device (e.g., battery) may be light weight. The weight of the battery may be relative to its dimensionality, capacity (Amph), voltage, cycle life, or any combination thereof, e.g., such as disclosed herein. The weight of the battery may be at most about 1.0 grams (gr), 1.5 gr, 2 gr, 5 gr, 8 gr, 10 gr, 50 gr, 100 gr, 150 gr, 200 gr, 250 gr, 500 gr, 700 gr, or 1000 gr. The weight of the battery may be of any value between the aforementioned values, e.g., from about 1 gr to about 1000 gr, from about 1 gr to about 50 gr, from about 10 gr to about 100 gr, from about 50 gr to about 500 gr, or from about 200 gr to about 1000 gr.

[0170] Fig. 28 shows schematic perspective view examples of energy manipulation devices such as batteries and battery cell architectures therein, relative to a Cartesian coordinate system. Example 2800 shows a cylindrical battery housing having a length 2802 and height 2801 , which is a diameter. The battery may comprise cell(s) that form a rolled sheet. In example 2800, each of the bottom and top faces of the cylinder has a smaller surface area as compared to the side surface of the cylinder - to the curved surface of the cylinder. Example 2830 shows a prismatic battery housing that is a rectangular prism, or a cuboid. The battery has length 2832, height 2831, and width 2833. Battery cells 2835 are stacked in the battery along height 2831, and along the Z direction. In example 2830, face XY has a larger surface area than face XZ, and face XY has a larger surface area than face YZ. Example 2850 shows a prismatic battery housing that is a rectangular prism, or a cuboid. The battery has length 2852, height 2851 , and width 2853. Battery cells 2835 are stacked in the battery along length 2852, and along the X direction. In example 2850, face XY has a larger surface area than face XZ, and face XY has a larger surface area than face YZ.

[0171] In some embodiments, the device such as battery comprises battery cells. The battery cells may be stacked along an axis referred to herein as the “stacking axis.” A dividing space may be disposed between every two immediately adjacent anode and cathode such that an anode contacts the first face of the dividing space, and a cathode contacts a second face of theAttorney Docket No. ENX-016Q.WOdividing space opposing its first space. The dividing space may comprise a separator such as disclosed herein. The dividing space may be configured to electrically separate the anode from the cathode, e.g., while allowing charge carriers to travel therethrough. The anode may comprise a current collector that is coated by an active material from one side, or from opposing sides of the current collector. A unit cell may comprise an anode - a dividing space (e.g., comprising a separator)- and a cathode. There may be a plurality of unit cells stacked along the stacking axis. The stack of cells may follow a pattern, the pattern may comprise a sequence. The sequence may comprise an arrangement of components of the battery cell with respect to each other. The sequence may comprise an anode, a separation space, a cathode, and a dividing space. The sequence may follow a CSAS pattern, or a CSASASCS pattern, with “C” designating a cathode, “A” designating an anode, “S” designating the dividing space, and “E” designates an end plate, e.g., see Fig. 29 for an example of stacked unit cells. The stacked cell may comprise current collector that is doubly covered with active material on its opposing sides, and mono-covered current collectors with active material having one side of the current collector covered with active material, the opposing side of the current collector is uncovered with active material. There may be two mono-covered current collectors in the cell assembly, e.g., at distal ends of the cell assembly. At least two of the mono-covered current collectors may be of the same type, e.g., of an anode type. At least two types of mono-covered current collectors may be of different types, e.g., of an anode type and of a cathode type. The cells may be stacked in one or more groups within the cell assembly (e.g., cell stack). Endplates may be disposed at distal ends of the cell assembly and along the stacking axis. Each of the distal endplates may be separated from the cell assembly by a respective nonconductor, e.g., any nonconductor disclosed herein. The nonconductor may or may not be of the separator material type. A plurality of electrodes of the same type may be coupled with a busbar. The busbar may be disposed (e.g., substantially) parallel to the stacking axis. In an example, anodes of the cell assembly are connected with an anode busbar. In an example, cathodes of the cell assembly are connected with a cathode busbar. The anode busbar and the cathode busbar may be (e.g., substantially) parallel to each other. The busbar may terminate by a terminal tab, e.g., that allows electrical connection to an exterior of the enclosure (e.g., can and / or pouch) in which the cell assembly is disposed. At least two components of the cell may extend in a direction (e.g., substantially) perpendicular to the stacking axis at a (e.g., substantially) same distance. At least two components of the cell may extend in a direction (e.g., substantially) perpendicular to the stacking axis (e.g., laterally) at a different distance from that axis. The different distance extension of the components can form a corrugated (e.g., misaligned) side face of the cell, andAttorney Docket No. ENX-016Q.WOof the set of cells, e.g., as depicted in Fig. 26, 2620. See also sides (e.g., edges) of cell sets in Fig. 29, examples 2900, and 2950. In an example, the cathode extends laterally less than the anode relative to the stacking axis, the extension being laterally in a direction perpendicular to the cell stacking axis. In an example, the separation space extends laterally more than the anode and / or more than the cathode, the extension being in a lateral direction perpendicular to the cell stacking axis. The distal endplates may couple with two opposing rigid constraint positions to generate the constraint system. The endplate and the rigid constraint portion (e.g., having perforations) may be of the same material type or of different material types. For example, the endplate and the rigid constraint portion may comprise stainless steel. For example, the rigid constraint portion may comprise stainless steel (e.g., SS-301 or SS-316), and the endplates may comprise aluminum. The rigid constraint portion may comprise stainless steel, biodur, nickel plating, electrodeposition coating, or Inconel. Any portion of the constraint system (e.g., the rigid constraint portion) may comprise a coating, e.g., a lacquer. The coating may comprise ClearClad, polyimide, or an electrodeposition coating. The rigid portion may be devoid of such coating. The electrodeposition coating may comprise Shimizu type coating. The coating may be configured to lessen (e.g., prevent) deposition of charge carrier plating such as lithium plating, e.g., during use of the cell assembly.

[0172] Fig. 29 shows a schematic cross-sectional example 2900 of a cell assembly comprising electrodes such as 2902, counter-electrodes such as 2905, separation spaces such as 2903, and nonconductors such as 2907. The battery cells are disposed in volume 2904 that includes a nonconductor, and together with the cell assembly, form an internal cell space. The internal cell space can be enclosure by a constraint system, e.g.., covering four consecutive faces of the internal cell space. The cells are stacked along an axis parallel to 2990, in a repeating ASCS arrangement that includes two distal counter-electrodes that comprises a single side counterelectrode active material coupled with a counter-electrode current collector. The rest of the counter-electrodes in the cell stack have counter-electrode active material doubly coated on their respective counter-electrode current collectors, and the electrodes in the cell stack have electrode active material doubly coated on their respective electrode current collectors. Each counter-electrode “A” in the battery includes a counter-electrode current collector such as 2913, the counter-electrode current collectors being coupled in parallel to a counter-electrode busbar 2914 (also herein “main counter-electrode current collector”), ending with counter-electrode contact forming a terminal tab 2911. Each electrode “C” in the battery includes an electrode current collector such as 2916, the electrode current collectors being coupled in parallel to an electrode busbar (also herein “main electrode current collector) 2917, ending with electrodeAttorney Docket No. ENX-016Q.WOcontact forming terminal electrode tab 2912. The cell stack includes distal endplates such as 2918 designated by “E”. Each of the endplate is separated from the cell assembly by Nonconductor “I” such as 2907. In example 2900, the terminal tabs emerge from a side of the internal cell space normal to the stacking axis, in which the electrode busbar and the counterelectrode busbar do not overlap. In example 2950, the terminal tabs emerge from a side of the internal cell space having a face parallel to the stacking axis. In such arrangement, the counterelectrode busbar may overlap (and thus may contact to form an electrical short) with the electrode busbar in a plane normal to the stacking axis, e.g., at 2960. Example 2950 shows an example in which terminal tabs 2961 and 2962 emerge from a side of the internal cell space. To facilitate this arrangement, electrode busbar 2964 is folded upon itself (e.g., makes a U turn) at the end of an end of the cell stack, and the counter-electrode busbar 2964a-c encircles (a) an opposing side to the side of the internal cell space from which the terminal tabs emerge in counter-electrode busbar portion 2964a, (b) a side normal to the stacking axis in counterelectrode busbar portion 2964b, and (c) a portion of the internal cell space from which the terminal tabs emerge in portion 2964c. To hinder (e.g., prevent) short of the electrode and counter-electrode busbars, to short the electrode assembly, separator I3 is disposed between the counter-electrode and electrode busbars. To electrically separate the distal current collector from the folded counter-electrode busbar, separator 2958 (I2) is disposed between the distal counter-electrode current collector and the busbar portion 2964b. To electrically separate the distal endplate 2918a from busbar portion 2964b, nonconductor 2957 (11) is disposed therebetween. The nonconductors 11 , I2, and I3 can be of any nonconductor disclosed herein. At least two the nonconductors among 11 , I2 and I3, are different in at least one nonconductor characteristics. At least two the nonconductors among 11, I2 and I3, are (e.g., substantially) the same in at least one nonconductor characteristics. The at least one characteristics comprises size, material content (e.g., chemical content), relative location to other component types, or any combination thereof. The electrode “C” can be a cathode and the counter-electrode “A” can be an anode, or vice versa. The busbar can have at least two of the portions 2964a, 2964b, and 2964c as a single entity. In an example, the electrode busbar has portions 2964a-c can be a single physical entity. The busbar can have at least two of the portions 2964a, 2964b, and 2964c as a separate entities that are electrically coupled, e.g., by welding. The busbar may be a connecting feature of the current collectors spanning one side of the internal cell space (e.g., 2964a), and the busbar extension can wrap around the other faces (e.g., 2964b and 2964c). Coupling of the busbar to the busbar extension can be outside of the face in which the busbar coupled with the terminal tabs of the respective current collectors, e.g., outside of 2964a. In anAttorney Docket No. ENX-0160.WOexample, the coupling between the busbar and the busbar extender is at 2964b. Coupling of the busbar to the busbar extension can be within the face in which the busbar coupled with the terminal tabs of the respective current collectors, e.g., in 2964a. In an example, the coupling between the busbar and the busbar extender is at 2964a.

[0173] The energy manipulation device is of a (e.g., Euclidean) three-dimensional (3D) geometric shape. The energy manipulation device may have an asymmetrical shape, e.g., its housing may be asymmetrical in shape. The Euclidean 3D shape may comprise a cylinder or a prism. The prism may be a Euclidean prism, or an amorphous prism. In some embodiments, the battery is a prismatic battery. In some embodiments, the battery is a cylindrical battery. The battery may have a first FLS such as a height (e.g., Fig. 28, 2831) of at least about 1 millimeter (mm), 2 mm, 3 mm, 5 mm, 6 mm, 8 mm, or 10 mm. The first FLS of the battery may be of any value between the aforementioned values, e.g., from about 1mm to about 10 mm. The battery may have a second FLS such as a length (e.g., Fig. 28, 2832) of at least about at least about 10 mm, 30 mm, 40 mm, 50 mm, 70 mm, 80 mm, 100 mm, 150 mm, or 200 mm. The battery may have a third FLS such as a width (e.g., Fig. 28, 2833) of at least about at least about 5 mm, 9 mm, 10 mm, 20 mm, 30 mm, 40 mm, 50 mm, 70 mm, 80 mm, 100 mm, 150 mm, or 200 mm. The third FLS of the battery may be of any value between the aforementioned values, e.g., from about 5 mm to about 200 mm. The battery may have an aspect ratio of the second FLS to the first FLS of at least about 1:1, 2:1, 4:1, 5:1, 8:1, 10:1 15:1 20:1 25:1 30:1 35:1 50:1 or 100:1. The battery may have an aspect ratio of the second FLS to the first FLS between the aforementioned values, e.g., from about 1:1 to about 10:1, from about 1:1 to about 50:1, from about 1:1 to about 100:1 or from about 2:1 to about 50:1. The FLS (e.g., from the first FLS and second FLS) may comprise a length, a width, a height, a diameter, or any other FLS such as disclosed herein.

[0174] In some embodiments, an energy manipulation (e.g., storage) device such as a battery, comprises a plurality of cells. Each of the cells comprises an anode separated by a gap from a cathode. The gap may comprise a separator. The cell may comprise one or more electrolyte types. Each of the electrodes (e.g., anode and cathode) comprises a current collector, e.g., a strip, a foil, or a film, of conductive material on which the active electrode material is disposed of. The conductive material may comprise an elemental metal, a metal alloy, or an allotrope of elemental carbon. In an example, the elemental metal comprises aluminum or copper. In an example, the metal alloy may comprise stainless steel. In an example, the allotrope of elemental carbon may comprise carbon nanotubes, or carbon fibers. The tubular structures (e.g., nanotubes) may comprise nestled tubes, e.g., at least about 2, 3, 4, or more nestled tubes. TheAttorney Docket No. ENX-016Q.WOcarbon fibers may be weaved, randomly dispersed, or any combination thereof. The strip of conductive material may or may not comprise a composite material. At least two cells in the energy manipulation device (e.g., battery) may be stacked in a direction (e.g., substantially) normal to their face having the largest surface area. The electrode has an electrode face having the largest surface area, and the counter-electrode has a counter-electrode face having the largest surface area. In some embodiments, there is a difference in a volume of the cell between a state of charge and a state of discharge of an electrode of the cell. The volume of the cell may repeatedly and / or reversibly alter between the state of charge and the state of discharge repeatedly. The reversible discharge may not be completely reversible, e.g., there may be an attrition in the properties of one or more components of the cell during a cycle of charge / discharge. The repeated cycling between the state of charge / discharge may comprise at least about 150 cycles, 200 cycles, 250 cycles, 300 cycles, 400 cycles, 500 cycles, 700 cycles, 800 cycles, 1000 cycles, 1200 cycles, or 1500 cycles. The repeated cycling between the state of charge / discharge may comprise any value of cycle between any of the aforementioned cycles, e.g., from about 150 cycles to about 1500 cycles. In some embodiments, there is a difference in a volume of the cell between a state of charge and a state of discharge of an electrode of the cell. The change in volume may comprise a change in at most about 20*, 25*, 50*, 100*, 200*, 300*, or 400* of an initial volume of the cell. The change in volume may comprise a change in at least about 10*, 25*, 50*, 100*, 200*, or 300* of an initial volume of the cell. The change in volume may comprise a change in any of the aforementioned values, e.g., from about 10* to about 400*, from about 100* to about 400*, or from about 20* to about 200*. The symbol “*” designates the mathematic operation of multiplication.

[0175] The energy manipulation device may comprise at least one constraint (e.g., a brace, or a harness). The constraint may be configured to (e.g., substantially) maintain constant dimensions and / or volume of the device during the charge / discharge operations. The constraint may be configured to maintain internal pressure in the device, e.g., during the charge / discharge operations. The internal overpressure in the device may be at most about 100 pounds per square inch (psi), 150 psi, 200psi, 500 psi, 1000 psi, 2000 psi, 3000 psi, 5000 psi, or 10000 psi. The internal overpressure in the device may be at most about 50 psi, 100 psi, 150 psi, 200 psi, 500 psi, 1000 psi, 2000 psi, 3000 psi, or 5000 psi. The internal overpressure in the device may be between the above referenced pressures, e.g., from about 50 psi to about 10000 psi, from about 50 psi to about 500 psi, or from about 50 psi to about 2000 psi, or from about 100 psi to about 3000 psi. The internal overpressure in the device may be greater than the ambient pressure external to the device, e.g., above 14.6 psi. In some embodiments, the energyAttorney Docket No. ENX-016Q.WOmanipulation device has a face type having the largest surface area among its face types. The face a face type having the largest surface area may deform (e.g., bend) during the, or as a consequence of, the overpressure phase. The face type having the largest surface area may (e.g., substantially) reversibly deform during the life of the device. Substantial reversal of the face’s deformation may be within the specification and / or intended use of the device.

[0176] In some embodiments, the battery cell set is disposed in an orthogonal stacked configuration.

[0177] In some embodiments, the device comprises a constraint system. The constraint system may be applied over one or both of the X-Y surfaces of the device (e.g., battery). In some embodiments, the constraint system includes a plurality of perforations to facilitate distribution (e.g., by flow of) an electrolyte solution after the cell, or cell set, has been assembled. In some embodiments, the casing comprises stainless steel, aluminum, titanium, beryllium, beryllium copper (hard), copper (O2 free, and / or hard), nickel, other metals or metal alloys, composite, polymer, ceramic, any plurality thereof, any combination thereof, or any other suitable material as applicable.

[0178] In some embodiments, the constraint system comprises (i) one or more endplates, (ii) one or more rigid constraint portions, (iii) an optional coating, (iv) an adhesive layer, or (v) any combination thereof. The optional coating may comprise a nonconductor. The optional coating may be configured to deter deposition of a reduced form of the charge carriers, e.g., may be configured to deter lithium plating on the constraint portion in which the coating is deposited. The constraint system may comprise any subset, or any combination, of the aforementioned components, e.g., depending at least in part on a design configuration of the cell assembly, operation conditions, and / or chemical makeup of the cell assembly such as of its active material. As used herein, the term “constraint system” refers to a structural assembly comprising one or more rigid constraint portions, one or more endplates, an optional insulating coating and / or adhesive layer. The term “constraint body” refers to the rigid portion of the constraint system comprising a planar middle section and two opposing flanges. The rigid portion and flanges of the constraint body can be made from a single unit of material, e.g., a bent sheet such as of metal.

[0179] In some embodiments, the constraint system is adapted to withstand pressure variation generated during cycling of the cell assembly. The pressure variation may include an overpressure as compared to the ambient environment external to the device such as battery. The pressure may be applied along a lateral direction of the constraint system, defined as perpendicular to a stacking axis of the cell assembly (e.g., Y-direction in Figs. 5 and 6). TheAttorney Docket No. ENX-0160.WOconstraint system may maintain structural integrity under pressure variation of at least about 450 pounds per square inch (psi), 500 psi, 600 psi, 700 psi, or 800 psi. The pressure variation may be at most about 900 psi, 1000 psi, 1100 psi, or 1200 psi. The pressure variation may be of any value between the aforementioned values, e.g., from about 500 psi to about 1200 psi, for example while minimizing permanent deformation of the constraint structure. The pressure variation may be measured along the lateral axis (e.g., X axis in figs. 5 and 6). The pressure variation may be measured relative to the pressure of the ambient environment (about 14.7 psi). The maximal pressure in the cell may differ based on the anode active material and the charge carriers used. For the case of lithium ions, Si-C may exert about half the pressure exerted by SiOx, e.g., Si-C may exert about 450 psi in a configuration, and SiOx about 1200 psi in an otherwise similar configuration.

[0180] In some embodiments, the constraint system is adapted to maintain dimensional stability of the cell assembly during volumetric change. The volumetric change may be associated with charge and discharge cycles of the cell assembly. The volumetric change undergone by the cell assembly constrained by the constraint system, may be at most about 2%, 3%, 5%, 8%, 10%, 12%, or 14%. The volumetric change may be of any value between the aforementioned values, e.g., from about 2% to about 14%, or from about 2% to about 10%. The volumetric change may be in accordance with applicable jurisdictional standards and / or industry standards. The standards may include dimensional change limits and / or mechanical strain thresholds defined by product safety or certification standards, e.g., UN 38.3, IEC 62133, UL 2580, or analogous regional standards.

[0181] Fig. 30 shows in example 3000 an exploded view of a pair of constraints 3001a and 3001b encasing a set (e.g., a population) of stacked battery cells 3002, the pair of constraints being part of a constraint system. Example 3050 shows an exploded view in which the two constraints 3001a-b are closer to the stacked cell set 3002. Fig. 30 is shown with respect to a Cartesian coordinate system. Each of the constraints may curb expansion of the battery cells during charge and / or discharge. Curbing the expansion may or may not be anisotropic. In the example shown in Fig. 30, the constraint can deter expansion of the cells anisotropically along the Y axis.

[0182] In some embodiments, the cell comprises an anode separated by a gap from an anode. The cell may comprise a separator disposed in the gap. The cells may be elongated, e.g., an elongated box. The face of the cell opposing the largest surface area face of the electrode (e.g., anode or cathode) may have an aspect ratio of at least about 10:1, 15:1, 20:1, 35:1, or 50:1, the aspect ratio being a length (e.g., Fig. 31, 3131) of the face to a height (e.g., Fig. 31, 3132) ofAttorney Docket No. ENX-016Q.WOthat face. The cell may have an aspect ratio between any of the aforementioned values, e.g., from about 10:1 to about 50:1 , the aspect ratio being the length of the cell to the height. The cell may have an aspect ratio of at least about 5:1, 8:1, 10:1, 15:1, 20:1, 25:1, 35:1, or 50:1, the aspect ratio being a height (e.g., Fig. 31, 3132) of the cell to a width (e.g., Fig. 31, 3104, showing a width of three cells). The cell may have an aspect ratio between any of the aforementioned values, e.g., from about 5:1 to about 50:1, the aspect ratio being the height of the cell to the width.

[0183] Fig. 31 shows in example 3100 a lateral portion of three cells, each comprising an electrode such as 3101, a counter electrode such as 3103, and a separator 3102 disposed between each immediately adjacent pair of electrode and counter electrode. In example 3100, the electrode (e.g., 3101) extends less than the counter electrode 3103 to the lateral edge 3104 of the stacked cells, with the separator extending more towards the edge than the electrode, and then the counter-electrode, e.g., thus forming a corrugated, or wavy, lateral edge 3104. Example 3130 shows a stack of cells, e.g., in which the cells are horizontally stacked. The stacking axis of the cells may be parallel to a face of the cell having the largest surface area, e.g., of a prismatic battery such as a rectangular box.

[0184] Example 3150 shows a set of stacked cells enclosed by two opposing casings 3152a and 3152b. Current collectors of the stacked cells are coupled with connectors 3153a and 3153b. 3153a connect to the electrodes of the set of cells, and 3153b connects to the counterelectrodes of the set of cells. The cells enclosed by the casings (e.g., housing or case), are further secured by a flexible material 3135, e.g., a band. The flexible material may comprise a polymer or a resin. The flexible material may be an electrical nonconductor. The casing may comprise one or more openings. The openings may be perforations. In the example of Fig. 31, casing 3152a includes oblong openings, e.g., that are evenly spaced along the X direction. Fig.31 is shown with respect to a Cartesian coordinate system.

[0185] In some embodiments, the cell is configured with at least one gap portion that can be occupied during expansion of the active material. The gap may be between the electrode and counter electrode, or adjacent to an edge (e.g., side) of the electrode. Some of the cells described herein comprise gaps located adjacent to the electrode(s), e.g., at side(s) of the electrode(s). These gaps may enable electrolyte to flow into the gaps, e.g., during buffering. Accordingly, when the starting material is added to the device (whether in an active or inactive state), the starting material can occupy these gaps.

[0186] In some embodiments, the interior of the casing is separated from an exterior of the casing, e.g., to hinder reactive specie(s) in the external environment to traverse to the interiorAttorney Docket No. ENX-016Q.WOenvironment such as to cause the harm. Terminals configured to conduct the electrical current flow are configured to allow electrical connectivity of the external environment with the cell(s) disposed in the interior of the housing. The housing comprises a seal to separate the interior environment of the housing from its exterior environment. The terminals extend through the seal from the interior of the housing to the external environment. Each of the terminals can be coupled with the housing (e.g., at the seal area) by coupler. The coupler may comprise a compressible material such as a malleable material. The terminal may be secured to the housing by an adhesive and / or thermosetting material, e.g., at the seal. The terminal may be secured to the seal at least in part by the adhesive and / or by the compressible material. The compressible material may be an adhesive. The compressible material and / or the adhesive, may comprise a polymer, a resin, a combination thereof, or a plurality of types thereof. The adhesive and / or thermosetting material, may be (e.g., substantially) confined to the seal. The adhesive may comprise polypropylene or epoxy glue. The susceptible material may participate in the chemistry of the device, e.g., of the cell. The susceptible material(s) may comprise any of the active materials of the cell, any electrolyte, any separator, any nonconductor, any divider, any current collector, any busbar, any adhesive, any plurality (e.g., of types or otherwise) thereof, or any combination thereof. The compressible material may be disposed in the seal, in an interior of the housing, in the exterior of the housing, or any combination thereof. In some embodiments, the terminal is compressed by the compressible material, which is compressed by the seal of the housing.

[0187] In some examples, the battery is disposed in a housing comprising a pouch. The pouch may insulate the battery content (e.g., the cell therein) from one or more reactive agent in the ambient environment external to the pouch. The pouch may enclosure the case of the battery, and the cell(s) housed therein. The pouch may comprise one or more layers. The one or more layers may include a material comprising a polymer, a resin, an elemental metal (e.g., strip, film, foil, and / or powder thereof), or a metal alloy (e.g., strip, film, foil, and / or powder thereof). The one or more layers may include one or more of these materials. The pouch may have an external surface having a color comprising black, silver, or white.

[0188] Fig. 32 shows an example of vertical cross sections of various batteries with respect to a Cartesian coordinate system, viewed from a side having a length and a height (e.g., Fig. 28, height 2851 and length 2852), and depicted as a cross section. Example 3200 shows battery cells such as cell 3202 stacked in a direction normal to the z axis, the battery having housing 3201. During a charge and discharge cycle, the battery expands and contracts. The expansion creates a force in the battery in a direction perpendicular to the stacking direction of the cellsAttorney Docket No. ENX-0160.WOand toward the edges of the battery (e.g., along arrows 3203), and in a direction along the stacking axis such as along 3204. Constraints 3207a and 3207b are coupled with the cell stack to curb expansion. The constraints may limit displacement along the direction of arrows 3203 and along 3204. The constrain may anisotropically constraint expansion of the cell stack. The constraints 3207a-3207b are disposed opposing each other and separated by a gap. Endplates 3206a and 3206b are disposed between the constraint and the cell stack. Each endplate may contact a distal end of the cell stack along the stacking direction. The endplates and the constraints may be arranged in a mirror symmetry about the stacking axis. The contraction and expansion may cause pressure buildup inside the battery. Heat may be generated during charge and discharge cycles, e.g., in interior of the cell stack such as along 3204. The heat may be dissipated from the battery along arrows 3203, increasing operational safety by reducing the risk of thermal runaway. Charge carriers generated from a precursor card may diffuse into the cell stack in the direction of arrow 3205 (e.g., from locations corresponding to arrows 3203). Diffusion of charge carriers may occur through perforations in the constraint system (e.g., perforation 3151 of Fig. 31).

[0189] In some embodiments, one or more cells are enclosed in a rigid enclosure. The rigid enclosure may comprise the constraint system and / or endplates. The enclosure may comprise an elemental metal, a metal alloy, an allotrope of elemental carbon, a polymer, a resin, a plurality of types thereof, or any combination thereof. The housing may be made of a material with greater, lesser, or (e.g., substantially) equal hardness compared to the enclosure. In an example, the housing may comprise a pouch having a lower hardness than a rigid enclosure such as a can. The pouch may be nested inside a harder housing (e.g., a can). A protective layer may be disposed between the enclosure and the housing, e.g., Fig. 31, 3151. The protective layer may comprise an elastic material, a polymer, a resin, a plurality of types thereof, or any combination thereof. The protective layer may form a band around the sides of the enclosure. The sides may include types with relatively smaller surface area. The protective layer may have a thickness, elasticity, and / or durability sufficient to cushion physical interaction between the housing and the enclosure. The protective layer may have a sponge-like geometry. The layer may be porous or non-porous. The protective layer may include polyurethane, polypropylene, polyethylene, and / or rubber. The layer may be attached to the enclosure by adhesion or by compression. The protective layer may be a pouch protective layer (PPL).

[0190] In an example, charge carriers and / or an electrolyte mixture are introduced into one or more cells from outside the cell assembly and within the housing. The entering materials may enter from outside the constraint system, outside the endplates, and / or from within the housingAttorney Docket No. ENX-0160.WO(e.g., pouch and / or can). Entry may occur from a seal of the housing (e.g., enclosure), a surface of the housing, or a protective cell layer. Entry may occur by diffusion along a concentration gradient. When the starting material enters from a side of the battery having the largest surface area (e.g., top or bottom surface in example 3150 of Fig. 31), diffusion may proceed inward toward the stack interior (e.g., towards 3204 and opposing the directions of arrows 3203 in Fig.32). Entry may be faster when the stack includes elongated cell components with a high aspect ratio of height (e.g., 2851) to width (e.g., 2853), disposed along a face-parallel axis. Entry from a constraint-facing direction (e.g., 3207a-3207b) may provide faster access to the cell assembly’s center, than entry from a direction orthogonal to 3203 (e.g., facing the wide surface of the electrodes).

[0191] Example 3250 shows battery cell 3252 rolled upon itself about an axis normal to the page (e.g., jelly roll configuration). Battery cell 3252 is disposed in housing 3251. During a charge and discharge cycle, the battery expands and contracts. Expansion generates force in the direction perpendicular to the roll axis and toward the battery edges (e.g., along arrows 3253). One or more constraints may be added to control the expansion. The contraction and expansion may produce internal pressure. Heat may accumulate in stack interior 3254. The heat may be released from the battery along arrows 3253. The stacked cell layout shown in example 3200 may provide improved thermal conductivity compared to the rolled configuration of example 3250. The stacked cell layout shown in example 3200 may provide improved diffusion for the entering materials compared to the rolled configuration of example 3250. The stacked cell layout shown in example 3200 may provide improved diffusion for the entering materials compared to the rolled configuration of example 3250.

[0192] In some embodiments, the battery is a rechargeable battery. The battery may undergo cycles of charge and discharge, with one cycle including one change and one discharge operation. The capacity of the battery to store and / or release electrical charge may diminish over the number of cycles it undergoes, e.g., at least in part due to various chemical reactions occurring in the battery during cycling. The reactions may comprise depletion of essential components such as essential chemical(s) for the function of the battery, e.g., depletion of the charge carriers. At least one essential component may be depleted during the first electrolytic cycle of the battery - during buffering, the essential component(s) may comprise starting material for passivation layer of the active material, e.g., SEI layer on an anode active material.

[0193] In some embodiments, the energy manipulation device (e.g., battery) contains critical component(s) required for operation of the cell. The component may comprise a chemical. The critical components may initially be in optimized relative amounts in the battery. Some of theAttorney Docket No. ENX-0160.WOcomponent(s) may enhance some performance attribute(s) while diminishing other attribute(s), e.g., making other attributes worse. A goal for cell performance could be to use an optimized amount of (e.g., critical) components to maximize the benefits while minimizing the drawbacks for best performance of the cell and / or device such as battery. Such optimization may differ in the buffering stage to the optimization in the performance stage - including at least two charging cycles.

[0194] For example, during charging of a cell, charge carriers move from the cathode to the anode. When charge carriers (e.g., lithium cations) come into contact with a starting material (e.g., FEC) they undergo a reduction reaction and form a stable solid electrolyte interphase (SEI) layer on the anode’s surface. The SEI layer (e.g., significantly) improves the cycling stability of the batteries such as by preventing electrolyte decomposition, e.g., on the anode surface. Although formation of the SEI layer is requested for the stability of the battery, some of the starting materials (e.g., FEC) and the charge carriers become irreversibly bound, and thus removed from the cyclic operation of the battery, e.g., the rechargeable battery. Problems can arise due to the expanding and contracting of the electrode active material such as of the anode. In an example, the SEI layer is formed during charging, when the anode is expanded to a first size. As the battery discharges, the anode contracts to a second smaller size. In some examples, the SEI layer is not sufficiently elastic and as the anode contracts, the SEI layer cracks and / or breaks, thus exposing portions of the anode active material. Such problem may be exacerbated in batteries with electrodes comprising materials (e.g., Si, SiOx, Si-C, etc.) that have large volume differences between their charged and discharged states. The silicon content in the electrode may be at least about 20%, 40%, 50%, 80%, 90%, 95%, 97%, 98%, or 99% wt / wt. The silicon content in the electrode may be between any of the aforementioned percentages, e.g., from about 20% to about 99%, or from about 80% to about 99% wt / wt. In the next charging cycle, the SEI layer may become mended (e.g., clogged) to fix the cracks in the SEI layer caused in the previous cycle. Mending the SEI layer may require additional starting material amount (e.g., FEC), e.g., and charge carriers. In such scenario, the cycle of charging and discharging the battery may result in continual consumption of the starting materials, e.g., and of charge carriers. Buffering may be used to replenish the consumed charge carriers in such case. However, there are currently inadequate solutions to replenish the starting materials required, e.g., the FEC. When the FEC concentration decreases in the electrolyte (e.g., to allow for more cycles of mending the SEI layer), the higher FEC concentration may decrease the efficiency of the battery and / or cause safety concerns for the battery. Higher concentration of FEC may result in generating gas, e.g., the higher the temperature experienced by the battery.Attorney Docket No. ENX-0160.WOConcentrations of FEC above 40% could form solids that decrease the efficiency of the battery. Higher concentration of FEC may increase the impedance of the battery and / or increase the viscosity of the electrolyte. Increasing the viscosity of the electrolyte can reduce the travel rate of the charge carriers in the battery. The gas generated may comprise hydrogen (H2), carbon dioxide (CO2), carbon monoxide (CO), methane (CH4), short aliphatic (e.g., CxH2X+2 such as ethane), or any combination thereof. The active FEC concentration can be most about 0.5%, 1%, 5%, 10%, 15%, or 30% v / v. The active FEC concentration can be between any of the aforementioned percentage values, e.g., from about 1% to about 20%, from about 0.25% to about 30%, from about 0.25% to about 5%, from about 5% to about 15%, or from about 15% to about 30%. In an example, the cell has at most about 15% active FEC available in the electrolyte mixture.

[0195] In some implementations, when a secondary battery is assembled, the amount of carrier ions available for cycling between the anode and the cathode is often initially provided in the cathode, because cathodically active materials, such as lithium cobalt oxide, are relatively stable in ambient air (e.g., they resist oxidation) compared to lithiated anode materials such as lithiated graphite. In some implementations, when a secondary battery is charged for the first time, the carrier ions may be extracted from the cathode and introduced into the anode. In some implementations, as a result, the anode potential may be lowered significantly (toward the potential of the carrier ions), and the cathode potential is increased (to become even more positive). In some implementations, these changes in potential may give rise to parasitic reactions on both the cathode and the anode, but sometimes more severely on the anode. In some implementations, a decomposition product comprising lithium (or other carrier ions) and electrolyte components, known as solid electrolyte interphase (SEI), may readily form on the surfaces of carbon anodes. In some implementations, these surfaces or covering layers may be carrier ion conductors, which establish an ionic connection between the anode and the electrolyte and prevent the reactions from proceeding any further.

[0196] In some implementations, although formation of the SEI layer is desired for the stability of a half-cell system comprising the anode and the electrolyte, a portion of the carrier ions introduced into the cells via the cathode is irreversibly bound and thus removed from cyclic operation, i.e. , from the capacity available to the user. In some implementations, as a result, during the initial discharge, fewer carrier ions may be returned to the cathode from the anode than was initially provided by the cathode during the initial charging operation, leading to irreversible capacity loss. In some implementations, during each subsequent charge and discharge cycle, the capacity losses resulting from mechanical and / or electrical degradation toAttorney Docket No. ENX-016Q.WOthe anode and / or the cathode may be much less per cycle. In some implementations, the relatively small carrier ion losses per cycle may contribute significantly to reductions in energy density and cycle life as the battery ages. In some implementations, chemical and electrochemical degradation may also occur on the electrodes and cause capacity losses. In some implementations, to compensate for the formation of SEI (or another carrier ionconsuming mechanism such as mechanical and / or electrical degradation of the negative electrode), additional or supplementary carrier ions may be provided from an auxiliary electrode after formation of the battery.

[0197] In some implementations, the positive electrode 208 of the secondary battery 100 (e.g., the collective population of the cathode structures 206 in the secondary battery 100) may have a reversible coulombic capacity that is matched to the discharge capacity of the negative electrode 209 (e.g., the collective population of the anode structures 207 in the secondary battery 100). In some implementations, the positive electrode 208 of the secondary battery 100 may be sized to have a reversible coulombic capacity that corresponds to the discharge capacity of the negative electrode 209 which, in turn, is a function of the negative electrode 209 end of discharge voltage.

[0198] In some implementations, the negative electrode 209 of the secondary battery 100 (e.g., the collective population of the anode structures 207 in the secondary battery 100) is designed to have a reversible coulombic capacity that exceeds the reversible coulombic capacity of the positive electrode 208. In some implementations, a ratio of the reversible coulombic capacity of the negative electrode 209 to the reversible coulombic capacity of the positive electrode 208 may be at least about 1.2:1, 1.3:1, 2:1, 3:1, 4:1, or 5:1, respectively. In some implementations, the excess coulombic capacity of the negative electrode 209 may advantageously provide a source of anodically active material to allow the secondary battery 100 to reversibly operate within a specified voltage that inhibits formation of crystalline phases (e.g., incorporating carrier ions) on the negative electrode 209 that reduce cycle-life of the negative electrode 209 as result of cycling.

[0199] In some implementations, the formation of SEI during the initial charge / discharge cycle reduces the amount of carrier ions available for reversible cycling. In some implementations, mechanical and / or electrical degradation of the negative electrode 209 during cycling of the secondary battery 100 may reduce the amount of carrier ions available for reversible cycling. In some implementations, to compensate for the formation of SEI (or another carrier ionconsuming mechanism such as mechanical and / or electrical degradation of the negative electrode), additional and / or supplementary carrier ions may be provided from an auxiliaryAttorney Docket No. ENX-0160.WOelectrode after formation of the secondary battery 100. In some implementations, an auxiliary electrode may be used to electrochemically transfer additional carrier ions to the positive electrode 208 and / or the negative electrode 209 of the secondary battery 100 during and / or after formation. In some implementations, the auxiliary electrode may be removed after transferring the additional carrier ions to the secondary battery 100 in order to improve the energy density of the secondary battery in its final form.

[0200] The passivation layer may result from an electrochemical reduction of electrolyte component(s) (e.g., FEC) at the electrode interface. The passivation layer may allow charge carriers (Li+) transport through the passivation layer while hindering (e.g., blocking) electron flow, e.g., to hinder (e.g., prevent) decomposition of other electrolyte components. The passivation layer may stabilize the active material (e.g., of the anode) at least in part by hindering (e.g., impeding or substantially preventing) direct contact between the electrons and the other electrolyte components, thus reducing degradation of the electrolyte and improving cycle life. The passivation layer may comprise inorganic salts, e.g., LiF, U2CO3, organic compounds (e.g., lithium alkyl carbonates, Fluoroethylene Carbonate (FEC) and vinylene carbonate (VC) polymerization products). Generation of the passivation layer may consume the charge carriers, e.g., irreversibly. Lithium may be converted into Lithium carbonate and lithium fluoride in the reduction reaction to form the passivation layer, which reaction may be irreversible.

[0201] In some embodiments, charge carriers (e.g., Li ions) reside in a cathode when the battery is in a discharged state, and reside in the anode when the battery is in a charged state. For example, when a battery charges, charge carriers (e.g., carrier ions) migrate into one or more electrode active materials. As the charge carriers traverse (e.g., move) in and out of the active material of the electrodes, the active material undergoes a volume change. The movement in an out of the active material may be referred to as ingress and egress of the charge carriers relative to the active material. The amount of expansion may differ depending on the active materials used for the electrode. For example, a graphite electrode may expand by about 6% to 10% when the graphite electrode is charged. In another example, a silicon electrode may expand up to 300% when the silicon electrode is charged. In another example, a silicon oxide electrode may expand up to 210% when the silicon oxide electrode is charged. In another example, an electrode comprising silicon may expand up to about 20%, 50%, 75%, 100%, 200%, 300%, or 350% when the silicon electrode is charged, the percentage being volume per volume. In some embodiments, graphite electrodes require less starting material (e.g., fluoroethylene carbonate (FEC)) than silicon electrodes because the graphite electrodesAttorney Docket No. ENX-0160.WOexpand less. The silicon anode material may have a capacity of at least about 1800 milliampere-hours per centimeter cubed (mAh / CC), 2000mAh / CC, or 2500mAh / CC. The graphite anode material may have a capacity of at most about 800 Amh / CC, 830mAh / CC, or 850mAh / CC.

[0202] In some embodiments, an energy manipulation device such as a battery, comprises a plurality of cells. Each of the cells comprises an anode separated by a gap from a cathode. The gap may comprise a separator. The cell may comprise one or more electrolyte types. Each of the electrodes (e.g., anode and cathode) comprises a current collector, e.g., a strip, a foil, or a film, of conductive material on which the active electrode material is disposed of. The conductive material may comprise an elemental metal, a metal alloy, or an allotrope of elemental carbon. In an example, the elemental metal comprises aluminum or copper. In an example, the metal alloy may comprise stainless steel. In an example, the allotrope of elemental carbon may comprise carbon nanotubes, or carbon fibers. The tubular structures (e.g., nanotubes) may comprise nestled tubes, e.g., at least about 2, 3, 4, or more nestled tubes. The carbon fibers may be weaved, randomly dispersed, or any combination thereof. The strip of conductive material may or may not comprise a composite material. At least two cells in the energy manipulation device (e.g., battery) may be stacked in a direction (e.g., substantially) normal to their face having the largest surface area. The electrode has an electrode face having the largest surface area, and the counter-electrode has a counter-electrode face having the largest surface area. In some embodiments, there is a difference in a volume of the cell between a state of charge and a state of discharge of an electrode of the cell. The volume of the cell may repeatedly and / or reversibly alter between the state of charge and the state of discharge repeatedly. The reversible discharge may not be completely reversible, e.g., there may be an attrition in the properties of one or more components of the cell during a cycle of charge / discharge. The repeated cycling between the state of charge / discharge may comprise at least about 200 cycles, 500 cycles, 800 cycles, 900 cycles, 1000 cycles, 1200 cycles, or 1500 cycles. In some embodiments, there is a difference in a volume of the cell between a state of charge and a state of discharge of an electrode of the cell. The change in volume may comprise a change in at most about 20%, 25%, 50%, 100%, 200%, 300%, or 400% of an initial volume of the cell. The change in volume may comprise a change in at least about 10%, 25%, 50%, 100%, 200%, or 300% of an initial volume of the cell. The change in volume may comprise a change in any of the aforementioned values, e.g., from about 10% to about 400%, from about 100% to about 400%, or from about 20% to about 200%. The charge carriers may interact with the active material (e.g., comprising silicon) such as in an intercalation and / or alloying processAttorney Docket No. ENX-0160.WO(e.g., Li-Si alloying). The Li-Si alloying may form alloys comprising LiisSi4 or LissSis. The lithium alloying of silicon may allow silicon to store at least 5*, 10*, or 15* more lithium as compared to graphite, with the operation “*” designating the mathematical operation of “times.”

[0203] In an example, a passivation layer is formed during operation of the device (e.g., during buffering) that consumes charge carriers and soluble passivating material in the cell. Portions of the passivation layer may be (e.g., additionally) formed during regular operation of the device, e.g., during charging and discharging cycles.

[0204] In some embodiments, electrons are formed in an operation of the cell, which electrons can further react with cell component(s). As the charge carriers move in the battery (e.g., in the cell), electrons are also moving. The electrons may travel from the current collector to the active material coupled with the current collector. When the active material contacts the current collector, such movement of electrons may be direct. When the active material does not contact the current collector, the movement may be indirect. The indirect movement may be through another active material (e.g., particle), through a conductor, or through a semiconductor. In an example, an allotrope of elemental carbon facilitates the movement of electrons from the current collector to the active material and / or from an active material mass of an electrode to another active material mass of the electrode. The allotrope of elemental carbon may comprise carbon nanotube, carbon fiber, any plurality of types thereof, or any combination thereof. The electrons may react with one or more chemicals in the device such as in the cell, e.g., some of which reactions may be detrimental to the battery’s chemistry such that they diminish (e.g., harm) the device’s requested performance. For example, the electrons may destabilize metal oxides during the charge / discharge cycles, e.g., due to slippage of transition metal layers, phase transitions and / or electrochemical strain. Mitigation (e.g., reduction) of the reactivity of the electrons in the battery cell may include causing confinement of the electrons to retard (e.g., reduce, deter and / or substantially prevent) reaction of the electrons with the material(s) in the device, e.g., during the prescribe operation conditions of the battery and / or during the prescribed lifetime of the battery. Generation of a passivation layer that helps confine the electrons in the active material mass and / or impede their reaction with components of the device (e.g., of the cell) external to the passivation layer, may mitigate the harmful reactivity of the electrons.

[0205] In some embodiments, the device has prescribed use conditions and / or a prescribed lifetime. Operation of the device (e.g., battery) may be during its prescribed lifetime, during its prescribed use, and / or according to jurisdictional standards relating to the device related standards. The prescribed lifetime may depend at least in part on the number of charge andAttorney Docket No. ENX-016Q.WOdischarge cycles, e.g., as disclosed herein. The number of cycles may be to full charge before the capacity of the device (e.g., battery) drops below 80%. The prescribed lifetime may be of at most about 3 years, 5 years, 6 years, 7 years, or 10 years, e.g., from the date of its manufacture. The device may have a shelf life of at least about 6 months, 12months, 15months, or 24 months. The standards may include, MIL-STD-810G (516.6), UL (e.g., UL1642 and / or UL 2054), SAE (e.g., SAE J2380), GB (e.g., GB31241 and / or GB31242), MSDS, UL (UL1642 and / or UL2054), CE, CB, UN (e.g., UN38.3 and / or UN38.4), RoHS, REACH, IEC (e.g., IEC 60068-2-6, IEC 60068-2, and / or IEC62133), DOT, IATA, GB, CTIA, PSE, SICIT, IEEE (e.g., IEEE 1726), CCC certification CN (e.g., CNS15265), BSMI, or any combination thereof. The prescribed operating conditions comprise temperatures between a lower temperature (e.g., -20°C) and a higher temperature (e.g., 80°C). The higher temperature may be of at most about 60°C, 70°C, 80°C, 85°C, or90°C. The higher temperature may be of at least about 40°C, 50°C, 55°C, 60°C, 70°C, or 80°C. The lower temperature may be of at most about -10°C, -20°C, -30°C, -40°C, or -50°C. The lower temperature may be of at least about -20°C, -10°C, or 0°C. The temperature may be between any of the aforementioned values, e.g., from about 60°C to about -20°C, or from about 90°C to about -40°C. The device may retain at least about 70%, 80%, or 85% of its capacity the lower temperature as compared to its capacity at ambient temperatures, e.g., at room temperature such as 20°C or 25°C.

[0206] In some embodiments, the energy manipulation device is rechargeable. The device may be configured to allow fast charging (e.g., allowing the cell(s) to fully charge in five minutes). The device may have a C-rate of at least about 0.2 C, 0.5 C, 1 C, 2 C, 3 C, 5 C, 7 C, 10 C, 12 C, or 15 C, 30 C, or 40 C. The C-rate may be charging the device to 80% capacity, or to 90% capacity. The device may have a C-rate of any value between any of the aforementioned values, e.g., from about 0.2 C to about 40 C, from about 2 C to about 5 C, from about 3 C to about 30 C, from about 10 C to about 40 C or from about 2 C to about 7 C. The device may be charged to at most about 30 seconds, 3 minutes, 6 minutes, 10 minutes, 12 minutes, 15 minutes, 30 minutes, the charging being to 80% or to 90% capacity. The device may allow to choose the mode of discharge and / or of charge. The discharge and / or of charge, may be in a continuous mode, in a pulsed mode, or in a combination of a continuous mode and pulsed mode. In some embodiments, the battery has a N / P ratio greater than one. The N / P ratio may be at least about 1.05, 1.1, or 1.15. The cell configuration, cell set architecture, and / or chemical makeup (e.g., of the electrode active material(s)), may allow for buffering such as pre-lithiation. The cell, cell set, and / or battery disclosed herein, may allow maintenance of cyclable charge carriers (e.g., lithium) in the anode, e.g., also at beginning of charge (BOC). The cell, cell set,Attorney Docket No. ENX-0160.WOand / or battery disclosed herein may provide for better conductivity and / or for lower overpotential in anode deposited material (e.g., cake comprising the active material). The cell, cell set, and / or battery disclosed herein may provide for reduced (a) cycling window and / or (b) damage due at least in part to expansion and contraction during the charge and discharged states of the cell. The cell, cell set, and / or battery disclosed herein may provide for high voltage at BOC, e.g., without buffering, e.g., without pre-loading of the charge carrier into the active material of the electrode such as in a pre-lithiation process. The nominal voltage of the device may be at least about 3.6 volts (V), 3.7 V, 3.8 V. The working voltage of the device may be at least about 3 V, 3.7 V, 3.8 V, 4.0 V, 4.2 V, 4.35 V, 4.5 V, 4.75 V, 4.9 V, or 5.0 V. The working voltage of the device may be between any of the aforementioned values, e.g., from about 3V to about 5V, from about 3V to about 4V, or from about 4V to about 5V. The weight of the device may be at most about 1 gram (gr), 1.5 gr, 1.8 gr, 2 gr, 3.5 gr, 6 gr, 46 gr, 47 gr, 50 gr, 69 gr, 70 gr, 71 gr, or 100 gr. The weight of the device may be at any value between any of the aforementioned values, e.g., from about 1.8 gr to about 100 gr. The volumetric energy density of the device may be at least about 500 Watt hour per liter (Wh / L), 600Wh / L, 800Wh / L, 805 Wh / L, 820 Wh / L, 900 Wh / L, 1300 Wh / L, or 1500 Wh / L. The gravimetric density of the device may be of any value between any of the aforementioned values, e.g., from about 500 Wh / L to about 1500 Wh / L. The gravimetric energy density of the device may be at least about 150 Watt hours per kilogram (Wh / Kg), 200 Wh / Kg, 250 Wh / Kg, 300 Wh / Kg, 320 Wh / Kg, 350 Wh / Kg, 395 Wh / Kg, 400 Wh / Kg, 500Wh / Kg, 1000 Wh / Kg, 2000 Wh / Kg or 3000 Wh / Kg. The gravimetric density of the device may be of any value between any of the aforementioned values, e.g., from about 150 Wh / Kg to about 3000 Wh / Kg, from about 200 Wh / Kg to about 400 Wh / Kg, or from about 400 to about 3000 Wh / Kg. The energy density (e.g., whether volumetric or gravimetric) may be measured at about 50%, 40%, 30% or 20% state of charge. The electrical charge capacity of the cell may be of at least about 200 milliampere hours (mAmph), 240 mAmph, 280 mAmph, 600 mAmph, 900 mAmph, 1 Amper hour (Amph), 5Amph, 7Amph, 7.35Amph, 10Amph, 30 Amph, 50 Amph, or 70 Amph. The electrical charge capacity of the cell may be between any of the aforementioned values, e.g., from about 200 mAmph to about 800 mAmph, from about 200 mAmph to about 1 Amph, from about 1 Amph to about 30 Amph, from about 1 Amph to about 10 Amph, or from about 30 Amph to about 80 Amph.

[0207] In some embodiments, the anode comprising silicon is thinner than an anode comprising graphite, e.g., has a smaller height - Fig. 27, 2705. The anode height may be at most about 30%, 35%, 40%, 50%, 65%, 75%, or 80%, height (i.e. , thickness) of a graphite anode for a for a given loading of anode active material. The anode height may be at least about 10%, 20%,Attorney Docket No. ENX-016Q.WO30%, 35%, 40%, 50%, 65%, or 70%, height (i.e., thickness) of a graphite anode for a for a given loading of anode active material. As compared to a graphite anode for a for a given loading of anode active material, the anode height may be between any of the aforementioned percentages, e.g., from about 10%, to about 70%, or from about 30% to about 70%. In an example, the height difference in graphite anode vs. silicon anode when discharged is 35%. In an example, the height difference in graphite anode vs. silicon anode is anode is 65% of the size of the graphite anode for a given loading, when each of the anodes is fully formed. A thinner anode may allow for better current distribution through the electrode and / or lower likelihood of charge carrier plating (e.g., reduction to its elemental state) such as lithium plating.

[0208] In some embodiments, the cell is pre-loaded with charge carriers, e.g., to form an initial passivation layer. During the initial charge process (e.g., buffering such as pre-lithiation), certain starting materials (e.g., FEC) are consumed to contribute to the formation of a passivation layer, e.g., an SEI layer. The passivation layer may be the result of the electrons and / or charge carriers reacting with the electrolyte in a reduction reaction. In some embodiments, the electrolyte(s) is / are chosen such that the reduction reaction results in the passivation layer having certain properties. For example, the passivation layer may comprise a solid or semisolid (e.g., gel). The passivation layer may be porous, e.g., to allow the charge carriers to migrate into and out of the electrode active material, e.g., silicon and / or graphite. The passivation layer may allow charge carriers (e.g., Li+) to pass through it while hindering (e.g., blocking) electron flow, to reduce (e.g., prevent) decomposition of electrolyte(s). The passivation layer may stabilize the active material, e.g., at least in part by hindering (e.g., preventing) direct contact of the electrode active material with any active components (e.g., of the electrolyte mixture), such that degradation of critical cell component(s) is reduced and / or the cycle life of the battery (e.g., the cell) is improved, in comparison to a situation in which no passivation layer is formed. The passivation layer may comprise a (e.g., inorganic) salt, an organic compound, a polymer, a resin, a composite, any plurality thereof, or any combination thereof. The salt may be the salt of the charge carrier. The organic compound may be made from a carbonate precursor. The organic compounds may comprise, or may be made of a precursor comprising, lithium alkyl carbonates, fluoroethylene carbonate (FEC), vinylene carbonate (VC), polymerization products thereof, a plurality of types thereof, or any combination thereof. In some embodiments, the passivation layer comprises a different chemical form of the charge carriers such as lithium. The passivation layer may (e.g., readily) form (e.g., deposit) on one or more surfaces of the active material of the cell, e.g., of the electrode and / or of the counter-electrode. The passivation layer may be a decomposition product comprising the charge carriers and / or electrolyte mixtureAttorney Docket No. ENX-0160.WOcomponents. Although formation of the passivation layer may be requested for the stability of the battery and / or cell thereof, some of the starting materials (e.g., FEC) and / or the electrons, may be irreversibly bound to the passivation layer, and thus are removed from regular operation of the cell, e.g., during its charge and discharge cycles.

[0209] In some embodiments, the cell comprises an electrolyte mixture. The electrolyte mixture may comprise salt, solvent, additive, any plurality of types thereof, or any combination thereof. The electrolyte mixture may be non-aqueous. The electrolyte mixture may comprise an organic mixture. The electrolyte may comprise polar molecule. The electrolyte may be sufficiently polar to dissolve the charge carriers such that they are readily available to participate in the charge and / or discharge cycles. The electrolyte may be such that side reaction with any other device components are minimized, e.g., during the prescribed lifetime of the device and / or in the prescribed use conditions of the device. The salt may comprise a halogen salt, a borate salt, an imide salt, a sulfonyl salt, any derivatives thereof, or any combination thereof. In the case of Lithium charge carrier, the salt may comprise Lithium hexafluorophosphate (LiPF6), Lithium tetrafluoro borate (LiBF4), Lithium bis(fluorosulfonyl)imide (LiFSI), any derivatives thereof, or any combination thereof. The solvent may comprise a carbonate, a propionate, an ethyl acetate, any derivatives thereof, or any combination thereof. The solvent may compromise Ethylene carbonate (EC), Propylene carbonate (PC), Ethyl methyl carbonate (EMC), Diethyl carbonate (DEC), Propyl Propionate (PP), Ethyl Propionate (EP), Difluoro ethyl acetate (DFEA), or Methyl (2 ,2,2-trifluoroethyl) carbonate (FEMC), any derivatives thereof, or any combination thereof. The additive may comprise a carbonate, a nitrile (e.g., mono, bi, and / or thri- nitrile), a cyanide, an ethoxy, an ethylene, a sultone, any derivatives thereof, or any combination thereof. The additive may comprise fluoroethylene carbonate (FEC), Vinylene carbonate (VC), Vinyl ethylene carbonate (VEC), Succinonitrile (SN), adiponitrile (AN), 1,3,6-hexanetricarbonitrile (HTCN), 1,2-Bis(2-cyanoethoxy) ethane (DENE), propane sultone (PS), 1,3-propene sultone (PRS), any derivatives thereof, or any combination thereof.

[0210] In some embodiments, the active material comprises a passivation layer. The passivation layer may range in thickness of at least about 30 nanometers (nm), 50nm, 100nm, 150 nm or 200nm. The passivation layer may range in thickness of at most about 50 nm, 100nm, 150nm, 200nm, or250nm. The passivation layer may range in thickness between any of the aforementioned values, e.g., from about 50 nanometers (nm) to about 150 nm, or from about 30nm to about 250nm. The passivation layer may be configured to allow charge carriers to pass through, and hinder (e.g., prevent) electrons in passing through.Attorney Docket No. ENX-016Q.WO

[0211] In some embodiments, the passivation layer comprises an SEI layer. The SEI layer may comprise the charge carrier such as lithium, e.g., in the form of salt(s) such as lithium fluoride (LiF) and / or U2CO3. In some embodiments, the SEI layer comprises inorganic salts, and / or organic compounds. The organic compounds may comprise lithium alkyl carbonates, fluoroethylene carbonate (FEC), vinylene carbonate (VC), polymerization products thereof, a plurality of types thereof, or any combination thereof. In some embodiments, the SEI layer comprises lithium. The SEI layer may (e.g., readily) form (e.g., deposit) on one or more surfaces of the electrode active material. The SEI layer may be a decomposition product comprising lithium (or other carrier ions) and / or electrolyte mixture components. Although formation of the SEI layer is requested for the stability of the battery, some of the starting materials of the passivation layer (e.g., FEC) and / or the electrons, may be irreversibly bound to the SEI, and thus are removed from the regular operation of the cell, e.g., during its charge and discharge cycles.

[0212] In some embodiments, a passivation layer is formed, the passivation layer contacting an external surface of the active material, e.g., cathode and / or anode active material. The concentration of the starting material in the electrolyte (e.g., FEC) in the electrolyte may be between about 15% to about 30% volume of active FEC per volume of electrolyte. The concentration of the starting material may be at most about 0.25%, 0.5%, 1%, 5%, 10%, 15%, or 30% volume of starting material per volume of electrolyte. For example, the concentration of starting material may be at most about 15% volume of starting material per volume of electrolyte. The concentration of starting material may be of any percentage value between any of the aforementioned percentage values, e.g., from about 0.25% to about 30%, from about 0.25% to about 5%, or from about 5% to about 15%, volume of starting material per volume of electrolyte.

[0213] In some embodiments, the cell comprises an anode separated by a gap from an anode. The cell may comprise a separator disposed in the gap. The cells may be elongated, e.g., may assume a shape of an elongated box. The face of the cell opposing the largest surface area face of the electrode (e.g., anode or cathode) may have an aspect ratio of at least about 10:1, 15:1, 20:1, 35:1, or 50:1, the aspect ratio being a length (e.g., Fig. 31, 3131) of the face to a height (e.g., Fig. 31, 3132) of that face. The cell may have an aspect ratio of at least about 5:1, 8:1, 10:1, 15:1, 25:1 20:1, 35:1, or 50:1, the aspect ratio being a height (e.g., Fig. 31, 3132) of the cell to a width.

[0214] In some embodiments, the architecture of the device comprising the stacked electrodes described herein (e.g., Figs. 28, 30, 32) allow for better (e.g., faster and / or homogenous)Attorney Docket No. ENX-0160.WOdistribution of starting materials (e.g., FEC) into the cell, as compared to other cell arrangements. The other cell arrangements may include a folded (e.g., jelly roll) cell configuration, or cell having a smaller aspect ratio, e.g., and having vertically stacked electrodes. In an example, when the electrodes have a large aspect ratio - are elongated, (e.g., and are stacked such along a horizontal axis such as in Fig. 28, 2850), starting materials introduced at the long edges of the electrodes (e.g., top and / or bottom of the device), may quickly reach the middle of the electrode height (e.g., 2850), e.g., since the distance to the interior of the cell structure is shorter, e.g., relative to a situation in which the starting material(s) is / are introduced (A) at the side edges of an elongated cylinder (e.g., 2800), or (B) at edges of electrodes having a smaller aspect ratio (e.g., and that are stacked along a vertical axis Fig. 28, 2830).

[0215] The prescribed use of the device (e.g., battery) comprises during charge-discharge cycling, during transportation, during storage, during maintenance, during upgrade, or any combination thereof. The prescribed use of the cell assembly comprises during formation of the cell assembly, during buffering of the cell assembly, during the prescribed use of the device comprising the cell assembly (e.g., the battery), or any combination thereof. The normal operation conditions of the device may be such that the device (e.g., minimally) abides by jurisdictional standards, and / or industry standards.

[0216] Fig. 5 is a perspective view of a buffer system 500 of an example embodiment, and Fig.6 is an exploded view of the buffer system 500. In some implementations, the buffer system 500 may be temporarily assembled during or after initial formation of the secondary battery 100 and the buffer system 500 is used to introduce additional carrier ions into the positive electrode 208 and / or the negative electrode 209 of the secondary battery 100 using an auxiliary electrode 502 (see Fig. 6). In some implementations, the buffer system 500 includes an enclosure 504 that encapsulates the auxiliary electrode 502 (see Fig. 6) and the secondary battery 100 within a perimeter 506 of the enclosure 504. In Fig. 5, the electrical terminals 124, 125 of the secondary battery 100 and a segment of a conductive tab 508-1 extend from the perimeter 506 of the enclosure 504, providing electrical connections to the auxiliary electrode 502 and the secondary battery 100. In some implementations, the enclosure 504 comprises a first enclosure layer 510 and a second enclosure layer 511 that are joined together to form the enclosure 504.

[0217] In Fig. 6, the first enclosure layer 510 has a perimeter 512 and the second enclosure layer 511 has a perimeter 513. Each of the enclosure layers 510, 511 may comprise a flexible or semi-flexible material, such as aluminum, polymer, a thin film flexible metal, or the like. In some implementations, one or more of the enclosure layers 510, 511 comprises a multi-layerAttorney Docket No. ENX-0160.WOaluminum polymer material, plastic, or the like. In some implementations, one or more of the enclosure layers 510, 511 comprises a polymer material laminated on a metal substrate, such as aluminum. In some implementations, the first enclosure layer 510 includes a pouch 514 (e.g., an indentation) that is sized and shaped to match the outer surface size and shape of the secondary battery 100.

[0218] The auxiliary electrode 502 partially surrounds the secondary battery 100 in the buffer system 500, and contains a source of carrier ions to replenish the lost energy capacity of the secondary battery 100 after formation (i.e. , to compensate for the loss of carrier ions upon the formation of SEI and other carrier ion losses in the first charge and / or discharge cycle of the secondary battery 100). In some implementations, the auxiliary electrode 502 may comprise a foil of the carrier ions in metallic form (e.g., a foil of lithium, magnesium, or aluminum), or any of the previously mentioned materials used for the cathodically active material layers 106 and / or the anodically active material layers 104 (see Fig. 2) in their carrier ion-containing form. In some implementations, the auxiliary electrode 502 may comprise lithiated silicon or a lithiated silicon alloy. When the buffer system 500 is assembled, the combination of the auxiliary electrode 502 and the secondary battery 100, which may be referred to as an auxiliary subassembly 516 (see Fig. 6), are inserted into the pouch 514, and the enclosure layers 510, 511 (e.g., cavity and its lid) are sealed together to form the buffer system 500 as depicted in Fig. 5. The specific details of the assembly process for the buffer system 500 and how the buffer system 500 is used during a carrier ion transfer process to the secondary battery 100 will be discussed in more detail below. In some implementations, the auxiliary electrode 502 includes an electrically conductive tab 508, which may be segmented into a conductive tab 508-2 that is covered by the enclosure 504 and a conductive tab 508-1 that is partially exposed by the enclosure as depicted in Fig. 5, for example, for ease of manufacturing.

[0219] Fig. 7 is a perspective view of the auxiliary electrode 502 of an example embodiment, and Fig. 8 is an exploded view of the auxiliary electrode. In Fig. 7, the auxiliary electrode 502 generally includes a separator 702, which covers a conductive layer 704 and carrier ion supply layers 706. When the auxiliary electrode 502 is formed into the shape depicted in Fig. 6, the carrier ion supply layers 706 are located proximate to major surfaces 126, 127 of the secondary battery 100 (see Fig. 1), with the separator 702 insulating the casing 116 of the secondary battery 100 from the conductive layer 704 and the carrier ion supply layers 706. The separator 702 includes an electrolyte, which facilitates the transfer of carrier ions from the carrier ion supply layers 706 to the secondary battery 100 during a buffer process.Attorney Docket No. ENX-016Q.WO

[0220] In Fig. 8, the auxiliary electrode 502 includes, from bottom to top in Fig. 8, the separator 702, the conductive layer 704, and the population of carrier ion supply layers 706. In some implementations, the auxiliary electrode 502 further includes the conductive tab 508-2, which is electrically conductive and electrically coupled with the conductive layer 704. The conductive tab 508-2 provides an electrical connection with the auxiliary electrode 502. In some implementations, the auxiliary electrode 502 is used during the buffer process to transfer carrier ions from the carrier ion supply layers 706 to the positive electrode 208 and / or the negative electrode 209 of the secondary battery 100 during or after formation of the secondary battery 100.

[0221] The separator 702 may comprise any of the materials previously described with respect to the separator layer 108 of the secondary battery 100. The separator 702 may be permeated with an electrolyte that serves as a medium to conduct carrier ions from the carrier ion supply layers 706 to the positive electrode 208 of the secondary battery 100 and / or the negative electrode 209 of the secondary battery. The electrolyte may comprise any of the materials previously described with respect to the secondary battery 100.

[0222] In some implementations, the separator 702 includes a first surface 802 and a second surface 803 that opposes the first surface 802. The surfaces 802, 803 of the separator 702 form major surfaces for the separator 702 and are disposed in the X-Y plane in Fig. 8. In some implementations, the separator 702 has a width 804 that extends in a direction of the Y-axis. In some implementations, the separator 702 is segmented in the width 804 into a first portion 805 and a second portion 806. In some implementations, the separator 702 may comprise a first separator layer 702-1 corresponding to the first portion 805 and a second separator layer 702-2 corresponding to the second portion 806.

[0223] In some implementations, the width 804 of the separator 702 is about 34 mm. In some implementations, the width 804 of the separator is about 30 mm, about 35 mm, or another suitable value. In some implementations, the width 804 of the separator 702 lies in a range of values of about 10 mm to about 200 mm, or some other suitable range that allows the separator 702 to function as described herein.

[0224] In some implementations, the separator 702, has a length 808 that extends in a direction of the X-axis. In some implementations, the length 808 of the separator 702 is about 72 mm. In some implementations, the length 808 of the separator 702 is about 65 mm, about 70 mm, about 75 mm, or some other suitable value that allows the separator 702 to function as described herein. In some implementations, the length 808 of the separator 702 lies in a rangeAttorney Docket No. ENX-016Q.WOof values of about 30 mm to about 200 mm, or some other suitable range of values that allows the separator 702 to function as described herein.

[0225] In some implementations, the separator 702 has a thickness 810 that extends in the direction of the Z-axis. In some implementations, the thickness 810 is a distance from the first surface 802 of the separator 702 to (and including) the second surface 803 of the separator. In some implementations, the thickness 810 of the separator 702 is about 0.025 mm. In some implementations, the thickness 810 of the separator 702 is about 0.015 mm, about 0.02 mm, about 0.03 mm, about 0.035 mm, or some other suitable value. In some implementations, the thickness 810 of the separator 702 lies in a range of values of about 0.01 mm to about 1.0 mm, or some other suitable range of values that allows the separator 702 to function as described herein.

[0226] The conductive layer 704 is electrically conductive, and may comprise a metal, a metalized film, an insulating base material with a conductive material applied thereto, or some other type of electrically conductive material. In some implementations, the conductive layer 704 comprises copper. In some implementations, the conductive layer 704 comprises aluminum or another metal. In some implementations, the conductive layer 704 is electrically coupled with the conductive tab 508-2, which is also electrically conductive. The conductive tab 508-2 has a first end 812 disposed proximate to the conductive layer 704 and a second end 813 disposed distal to the conductive layer 704 that opposes the first end 812. The first end 812 of the conductive tab 508-2 is electrically coupled to the conductive layer 704. In some implementations, the first end 812 of the conductive tab 508-2 is spot-welded to the conductive layer 704. In some implementations, the first end 812 of the conductive tab 508-2 is soldered to the conductive layer 704. In some implementations, the conductive tab 508-2 may be affixed at the first end 812 to the conductive layer 704 using any suitable means that ensure a mechanical connection and an electrical connection to the conductive layer. The conductive tab 508-2 may comprise any type of electrically conductive material as desired. In some implementations, the conductive tab 508-2 comprises a metal. In some implementations, the conductive tab 508-2 may comprise nickel, copper, aluminum, or other suitable metals or metal alloys that allows the conductive tab 508-2 to function as described herein.

[0227] In some implementations, the conductive layer 704 includes a first surface 814 and a second surface 815 that opposes the first surface 814. The surfaces 814, 815 of the conductive layer 704 form major surfaces for the conductive layer 704 and are disposed in the X-Y plane in Fig. 8. In some implementations, the conductive layer 704 has a width 816 that extends in a direction of the Y-axis. In some implementations, the width 816 of the conductive layer 704 isAttorney Docket No. ENX-0160.WOabout 15 mm. In some implementations, the width 816 of the conductive layer 704 is about 10 mm, about 20 mm, or some other suitable value that allows the conductive layer 704 to function as described herein.

[0228] In some implementations, the width 816 of the conductive layer 704 lies in a range of values of about 5 mm to about 100 mm, or some other suitable range of values that allows the conductive layer 704 to function as described herein. In some implementations, the first surface 814 of the conductive layer 704 is segmented into a first region 818-1 , disposed proximate to a first end 820 of the conductive layer 704, a second region 818-2, disposed proximate to a second end 821 of the conductive layer 704, and a third region 818-3 disposed between the first region 818-1 and the second region 818-2.

[0229] The conductive layer 704 has a length 822 that extends in a direction of the X-axis. In some implementations, the length 822 of the conductive layer 704 is about 70 mm. In some implementations, the length 822 of the conductive layer 704 is about 60 mm, about 65 mm, about 75 mm, or some other suitable value that allows the conductive layer 704 to function as described herein. In some implementations, the length 822 of the conductive layer 704 lies in a range of values of about 30 mm to about 200 mm, or some other suitable range of values that allows the conductive layer 704 to function as described herein.

[0230] The conductive layer 704 has a thickness 824 that extends in a direction of the Z-axis. In some implementations, the thickness 824 is a distance from the first surface 814 of the conductive layer 704 to (and including) the second surface 815 of the conductive layer 704. In some implementations, the thickness 824 of the conductive layer 704 is about 0.1 mm. In some implementations, the thickness 824 of the conductive layer 704 is about 0.005 mm, about 0.15 mm, or about 0.2 mm. In some implementations, the thickness 824 of the conductive layer 704 lies in a range of values of about 0.01 mm to about 1.0 mm, or any other suitable range for the thickness that allows the conductive layer 704 to function as described herein.

[0231] In some implementations, the carrier ion supply layers 706, which comprise a population of carrier ion supply layers 706, comprise any carrier ion containing material previously described that may be utilized to supply carrier ions to the positive electrode 208 and / or the negative electrode 209 of the secondary battery 100. The carrier ion supply layers 706 may comprise one or more sources of lithium ions, sodium ions, potassium ions, calcium ions, magnesium ions, and aluminum ions. In some implementations, the carrier ion supply layers 706 are disposed within the first region 818-1 and the second region 818-2 of the conductive layer 704. In some implementations, the carrier ion supply layers 706 are also disposed in the third region 818-3 of the conductive layer 704.Attorney Docket No. ENX-0160.WO

[0232] In some implementations, the carrier ion supply layers 706 include a first surface 826 and a second surface 827 that opposes the first surface 826. The surfaces 826, 827 of the carrier ion supply layers 706 form major surfaces for the carrier ion supply layers 706 and are disposed in the X-Y plane in Fig. 8. In some implementations, the carrier ion supply layers 706 have a width 828 that extends in a direction of the Y-axis. In some implementations, the width 828 of the carrier ion supply layers 706 are about 15 mm. In some implementations, the width 828 of the carrier ion supply layers 706 are about 10 mm, about 20 mm, or some other suitable value that allow the carrier ion supply layers 706 to function as described herein. In some implementations, the width 828 of the carrier ion supply layers 706 lies in a range of values of about 5 mm to about 100 mm, or some other suitable range of values that allows the carrier ion supply layers 706 to function as described herein.

[0233] In some implementations, the carrier ion supply layers 706, have a length 830 that extends in a direction of the X-axis. In some implementations, the length 830 of the carrier ion supply layers 706 are about 23 mm. In some implementations, the length 830 of the carrier ion supply layers 706 are about 15 mm, about 20 mm, about 25 mm, or some other suitable length that allows the carrier ion supply layers 706 to function as described herein. In some implementations, the length 830 of the carrier ion supply layers 706 lie in a range of values of about 10 mm to about 100 mm, or some other suitable range of values that allow the carrier ion supply layers 706 to function as described herein.

[0234] In some implementations, the carrier ion supply layers 706 each have a thickness 832 that extends in a direction of the Z-axis. In some implementations, the thickness 832 is a distance between the first surface 826 of the carrier ion supply layers 706 and the second surface 827 of the carrier ion supply layers 706. In some implementations, the thickness 832 of the carrier ion supply layers 706 are about 0.13 mm. In some implementations, the thickness 832 of the carrier ion supply layers 706 are about 0.005 mm, about 0.15 mm, or about 0.2 mm. In some implementations, the thickness 832 of the carrier ion supply layers 706 lie in a range of values of about 0.01 mm to about 1.0 mm, or any other suitable range of values for the thickness 832 that allows the carrier ion supply layers 706 to function as described herein.

[0235] In some implementations, the carrier ion supply layers 706 are separated from each other by a distance 834, corresponding to the third region 818-3. In some implementations, the distance 834 is about 23 mm. In some implementations, the distance 834 is about 15 mm, about 20 mm, about 25 mm, or about 30 mm. In some implementations, the distance 834 lies in a range of values of about 10 mm to about 50 mm, or any other suitable range of values that allows the carrier ion supply layers 706 to function as described herein.Attorney Docket No. ENX-0160.WO

[0236] In some implementations, the carrier ion supply layers 706 are sized to be capable of providing at least 15% of the reversible coulombic capacity of the positive electrode 208 of the secondary battery 100. In some implementations, the carrier ion supply layers 706 are sized such that they contain sufficient carrier ions (e.g., lithium, magnesium, or aluminum ions) to provide at least 30% of the reversible coulombic capacity of the positive electrode 208 of the secondary battery 100. In some implementations, the carrier ion supply layers 706 are sized such that they contain sufficient carrier ions to provide at least 100% of the reversible coulombic capacity of the positive electrode 208 of the secondary battery 100. In some implementations, the carrier ion supply layers 706 are sized such that they contain sufficient carrier ions to provide at least 200% of the reversible coulombic capacity of the positive electrode 208 of the secondary battery 100. In some implementations, the carrier ion supply layers 706 are sized such that they contain sufficient carrier ions to provide at least 300% of the reversible coulombic capacity of the positive electrode 208 of the secondary battery 100. In some implementations, the carrier ion supply layers 706 are sized such that they contain sufficient carrier ions to provide about 100% to about 200% of the reversible coulombic capacity of the positive electrode 208 of the secondary battery 100.

[0237] During an assembly process for the auxiliary electrode 502, the separator 702 may be cut from stock material or prefabricated to achieve the width 804 and the length 808 as shown in Fig. 8. The conductive layer 704 may be cut from stock material or prefabricated to achieve the width 816 and the length 822 shown in Fig. 8. In some implementations, the conductive layer 704 is prefabricated to include the conductive tab 508-,2 with the first end 812 mechanically and electrically affixed to the conductive layer 704 as depicted in Fig. 8. In some implementations, the conductive tab 508-2 is cut from a stock material and mechanically and electrically coupled with the conductive layer 704 (e.g., by spot welding or soldering first end 812 to the conductive layer 704). In some implementations, the carrier ion supply layers 706 are cut to size from stock materials, and bonded or otherwise laminated to the conductive layer 704 (e.g. by cold welding the carrier ion supply layers 706 onto the conductive layer 704) to achieve the orientation depicted in Fig. 8, with the second surface 827 of the carrier ion supply layers 706 in contact with the first surface 814 of the conductive layer 704. In some implementations, the material used to form the carrier ion supply layers 706 (e.g., lithium) may exist in stock form as rolls of lithium sheets that are cut to size.

[0238] In some implementations, the conductive layer 704 is prefabricated to include the carrier ion supply layers 706 arranged in the orientation depicted in Fig. 8. In some implementations, the conductive layer 704 is disposed within the first portion 805 of the separator 702 in aAttorney Docket No. ENX-0160.WOdirection of the X-axis, with the second surface 815 of the conductive layer 704 contacting the first surface 802 of the separator 702.

[0239] Fig. 9 is a perspective view of the auxiliary electrode 502 at an intermediate stage of the fabrication process for the auxiliary electrode. At this stage, the conductive layer 704 is disposed on the first portion 805 of the separator 702, and the conductive tab 508-2 extends to the left (in the Y-axis direction) in Fig. 9 from the first end 812, which is affixed to the conductive layer 704, away from the separator 702 and the conductive layer 704 towards the second end 813. The first surface 802 of the separator 702 is covered by the conductive layer 704 within the first portion 805 of the separator 702, while the first surface 802 of separator remains uncovered within the second portion 806 of the separator 702.

[0240] In some implementations, to continue the fabrication process of the auxiliary electrode 502, the second portion 806 of the separator 702 is folded in the direction of an arrow 902 towards the left (about an axis parallel to the X-axis) in Fig. 9, such that the first surface 802 within the second portion 806 of the separator 702 contacts the first surfaces 826 of the carrier ion supply layers 706 and the first surface 814 of the conductive layer 704 that is exposed between the carrier ion supply layers 706. When the separator 702 comprises the first separator layer 702-1 and the second separator layer 702-2, the second separator layer may be placed such that the first surface 802 of the second separator layer contacts the first surfaces 826 of the carrier ion supply layers 706 and the first surface 814 of the conductive layer 704 that is exposed between the carrier ion supply layers 706.

[0241] Fig. 10 is a perspective view of the auxiliary electrode 502 at another intermediate stage in the fabrication process, after folding the second portion 806 of the separator 702 as described above. At this stage, the separator 702 encapsulates the conductive layer 704 and the carrier ion supply layers 706, leaving a portion between the first end 812 of the conductive tab 508-2 and the second end 813 of the conductive tab 508- 2 uncovered by the separator 702. The separator 702 may then be bonded to itself along at least a portion of an outer perimeter 1002 of the separator to encapsulate the conductive layer 704 within the first portion 805 of the separator and the second portion 806 of the separator along the first surface 802 of the separator (not visible in Fig. 10).

[0242] In some implementations, the separator 702 is bonded to itself along at least a portion of an outer perimeter 1002 of the separator using a hot melt process, a welding process, a bonding process, etc. In Fig. 10, the auxiliary electrode 502 at this stage includes a first side 1004 and a second side 1005 that opposes the first side 1004. The first side 1004 includes the second surface 803 of the separator 702, which covers the carrier ion supply layers 706 in firstAttorney Docket No. ENX-0160.WOregion 818-1 proximate to first end 820 of the conductive layer 704 (not visible in Fig.10) and the second region 818-2 proximate to the second end 821 of the conductive layer 704 (not visible in this view). In Fig. 10, the first region 818-1 is proximate to the first end 812 of the conductive tab 508-2 and the second region 818-2 is disposed away from the first end 812 of the conductive tab 508-2. The first end 812 of the conductive tab 508-2 is electrically coupled to the conductive layer 704 within the third region 818-3 of the conductive layer 704. In some implementations, the conductive tab 508 may be extended (e.g., with the conductive tab 508-1 , as shown in Fig.11, which depicts the auxiliary electrode 502 after assembly).

[0243] In response to fabricating the auxiliary electrode 502, performing a fabrication process for the buffer system 500 (see Figs. 6 and 7) continues as follows. Figs. 12-16 are perspective views of the buffer system 500 during various stages in a fabrication process. In Fig. 12, the second region 818-2 of the auxiliary electrode 502 is inserted into the pouch 514 of the first enclosure layer 510, with the second side 1005 of the auxiliary electrode disposed towards the first enclosure layer 510 within the pouch 514 and the first side 1004 of the auxiliary electrode disposed away from the first enclosure layer 510 within the pouch 514. The third region 818-3 and the first region 818-1 of the auxiliary electrode 502 extend away from the pouch 514 in the direction of the Y-axis.

[0244] With the auxiliary electrode 502 oriented within the pouch 514 as depicted in Fig. 12, the secondary battery 100 is placed on the auxiliary electrode 502 within the pouch 514, which corresponds to the second region 818-2 of the auxiliary electrode 502 (see Fig. 13). In some implementations, the first major surface 126 of the secondary battery 100 (see Fig. 1, not visible in Fig. 13) contacts the auxiliary electrode 502 within the pouch 514 and the second major surface 127 of the secondary battery is disposed away from the auxiliary electrode 502. The electrical terminals 124, 125 of the secondary battery 100 extend away from the pouch 514 in the direction of the Y-axis in Fig.13, placing the electrical terminals outside of the perimeter 512 of the first enclosure layer 510. In some implementations, at a stage of the fabrication process for the buffer system 500, an electrolyte is added to the pouch 514. In some implementations, the separator 702 of the auxiliary electrode 502 is pre-impregnated with the electrolyte.

[0245] With the secondary battery 100 loaded onto the second region 818-2 of the auxiliary electrode 502 within the pouch 514, the auxiliary electrode 502 is folded in the direction of an arrow 1302 in order to position the first side 1004 of the first region 818-1 of the auxiliary electrode 502 in contact with the second major surface 127 of the secondary battery 100, the result of which is depicted in Fig. 14. In this configuration, both major surfaces 126, 127 of the secondary battery 100 (see Fig. 1) are electrochemically coupled with the carrier ion supplyAttorney Docket No. ENX-0160.WOlayers 706 of the auxiliary electrode 502, using the separator 702 (see Figs. 7-11) and an electrolyte disposed between each of the major surfaces 126, 127 of the secondary battery 100 and the carrier ion supply layers 706.

[0246] Fig. 15 is a cross-sectional view of the buffer system 500 along cut lines A-A of Fig. 14. In this view, the layers of the buffer system 500 at the pouch 514 of the first enclosure layer 510 are visible. In particular, Fig. 15 illustrates the placement of the secondary battery 100 and the auxiliary electrode 502 in the pouch 514, and specifically, from top to bottom in stacked succession, the separator 702, the conductive layer 704, one of the carrier ion supply layers 706, the separator 702, and the second major surface 127 of the secondary battery 100 at the casing 116. Fig. 15 further illustrates, from bottom to top in stacked succession, the first enclosure layer 510, the separator 702, the conductive layer 704, one of the carrier ion supply layers 706, the separator 702, and the first major surface 126 of the secondary battery 100 at the casing 116.

[0247] With the secondary battery 100 sandwiched by the auxiliary electrode 502 within the pouch 514 as illustrated in Fig. 15, the second enclosure layer 511 is aligned to the first enclosure layer 510, as depicted in Fig. 16. After proper placement of the second enclosure layer 511 relative to the first enclosure layer 510, the enclosure layers 510, 511 (e.g., forming a cover and its lid) are sealed along a sealing line 1602 (denoted by the dashed line in Fig. 16) to form the enclosure 504. The enclosure layers 510, 511 may be sealed along the sealing line 1602 by welding, heat sealing, adhesive, thermosetting material, combinations thereof, or the like. In some implementations, the enclosure layers 510, 511 may be sealed along three sides of the sealing line 1602 creating a pocket therein. In some implementations, the secondary battery 100 may be placed within the pocket, and the final edge of the sealing line 1602 is subsequently sealed. In some implementations, the sealing line 1602 is sealed using a hot press, that applies a controlled temperature and pressure to the sealing line 1602 causing the enclosure layers 510, 511 to adhere or fuse together along the sealing line 1602. In some implementations, a vacuum is applied to the secondary battery 100 during the sealing process to evacuate any excess volume occupied by air or other gas. The time for which the sealing line 1602 is subject to the hot press may be controlled and is dependent upon the materials selected for the enclosure layers 510, 511. Once sealed over the secondary battery 100, the sealed enclosure layers 510, 511 form the buffer system 500. Upon sealing, the buffer system 500 is liquid tight and / or air-tight, depending on the desired application. The electrical terminals 124 and 125 of the secondary battery 100 and the conductive tab 508-1 remain exposed and are notAttorney Docket No. ENX-0160.WOcovered by the enclosure layers 510, 511 to allow for a subsequent buffer process to be applied to the secondary battery 100.

[0248] With the secondary battery 100 and the carrier ion supply layers 706 of the auxiliary electrode 502 (not visible in Fig. 16) electrochemically coupled together within the enclosure 504 of the buffer system 500, a carrier ion buffer process is performed on the secondary battery 100 during or after initial formation of the secondary battery 100. In some implementations, this carrier ion buffer process transfers carrier ions from the carrier ion supply layers 706 of the auxiliary electrode 502 into each of the first major surface 126 of the secondary battery 100 and the second major surface 127 of the secondary battery 100 (see Fig. 15). In some implementations, transferring the carrier ions to the secondary battery 100 from both major surfaces 126, 127 of the secondary battery 100, as depicted in Fig. 15, provides a technical benefit of distributing the forces generated by anode and / or cathode swelling more equally across the casing 116 of the secondary battery 100 as more carrier ions are loaded into the anode and / or the cathode of the secondary battery 100.

[0249] Either prior to inserting the secondary battery 100 into the buffer system 500, or after, the secondary battery 100 is charged (e.g., via the electrical terminals 124, 125) by transferring carrier ions from the cathode structures 206 of the secondary battery to the anode structures 207 of the secondary battery. Charging may be discontinued when the positive electrode 208 of the secondary battery 100 reaches its the end-of-charge design voltage. During the initial charging cycle, SEI may form on the surfaces of the anode structures 207 of the secondary battery 100. To compensate for the loss of carrier ions to SEI, and to further provide additional carrier ions to mitigate the long term secondary reactions during cycling where carrier ions are lost due to side reactions, the positive electrode 208 and / or the negative electrode 209 of the secondary battery 100 may be replenished by applying a voltage across the auxiliary electrode 502 and the cathode structures 206 and / or the anode structures 207 (e.g., via the conductive tab 508-1 of the auxiliary electrode 502 and one of the electrical terminals 124, 125) to drive carrier ions from the carrier ion supply layers 706 of the auxiliary electrode 502 to the cathode structures 206 and / or the anode structures 207 of the secondary battery 100. Once the transfer of carrier ions from the auxiliary electrode 502 to the secondary battery 100 is complete, the negative electrode 209 of the secondary battery 100 is again charged, this time with carrier ions transferred from the cathode structures 206 of the secondary battery 100 to the anode structures 207 of the secondary battery.

[0250] In some implementations, the amount of carrier ions transferred from the auxiliary electrode 502 to the secondary battery 100 during the buffer process is about 50% of theAttorney Docket No. ENX-016Q.WOreversable columbic capacity of the positive electrode 208 of the secondary battery 100. In some implementations, the amount of carrier ions transferred from the auxiliary electrode 502 to the secondary battery 100 during the buffer process is about 55%, about 60%, about 65%, about 70%, about 75%, about 80%, about 85%, about 90%, about 95%, or about 100% of the reversable columbic capacity of the positive electrode 208 of the secondary battery 100. In some implementations, the amount of carrier ions transferred from the auxiliary electrode 502 to the secondary battery 100 lies in a range of values of about 1% to about 100% of the reversable columbic capacity of the positive electrode 208 of the secondary battery 100. In some implementations, the negative electrode 209 of the secondary battery 100 has about 170% of the reversable columbic capacity of the positive electrode 208 of the secondary battery 100 stored as carrier ions when the secondary battery 100 is charged, and about 70% of the reversable columbic capacity of the positive electrode 208 of the secondary battery 100 stored as carrier ions when the secondary battery 100 is discharged. An excess of carrier ions at the negative electrode 209 of the secondary battery 100 provided during the buffer process provides a technical benefit of mitigating the loss of carrier ions at the secondary battery 100 due to SEI at initial formation. Further, an excess of carrier ions at the negative electrode 209 of the secondary battery 100 provided during the buffer process provides a technical benefit of mitigating the loss of carrier ions at the secondary battery 100 due to side reactions that deplete carrier ions in the secondary battery 100 as the secondary battery 100 is cycled during use, which reduces the capacity loss of the secondary battery 100 over time.

[0251] In some implementations, transferring carrier ions from the auxiliary electrode 502 to the secondary battery 100 may occur concurrently with an initial formation of the secondary battery 100 (e.g., during the first charge of the secondary battery 100), and / or during a subsequent charge of the secondary battery 100 after initial formation. In some implementations, carrier ions are transferred from the positive electrode 208 of the secondary battery 100 to the negative electrode 209 of the secondary battery 100. Concurrently with or based on a temporal delay or a temporal pattern, carrier ions are transferred from the auxiliary electrode 502 to the positive electrode 208 and / or the negative electrode 209 of the secondary battery 100.

[0252] In some implementations, the positive electrode 208 may be replenished with carrier ions by simultaneously transferring carrier ions from the auxiliary electrode 502 to the positive electrode 208 of the secondary battery 100, while also transferring carrier ions from the positive electrode 208 of the secondary battery 100 to the negative electrode 209 of the secondary battery 100. In Fig. 6, a voltage is applied across the electrical terminals 124, 125 of the secondary battery 100, to drive carrier ions from the positive electrode 208 to the negativeAttorney Docket No. ENX-0160.WOelectrode 209 of the secondary battery 100. While the carrier ions are being transferred from the positive electrode 208 to the negative electrode 209, a voltage is applied across the conductive tab 508-1 of the auxiliary electrode 502 and the positive electrode 208 of secondary battery 100 to drive carrier ions from the auxiliary electrode 502 to the positive electrode 208 of the secondary battery 100. Thus, carrier ions are transferred from the auxiliary electrode 502 to the positive electrode 208 of the secondary battery 100 at the same time that carrier ions are being transferred from the positive electrode 208 to the negative electrode 209 of the secondary battery 100. That is, a voltage is maintained across the positive electrode 208 and the negative electrode 209 of the secondary battery 100 that is sufficient to drive carrier ions from the positive electrode 208 to the negative electrode 209 of the secondary battery 100, at the same time that a voltage is maintained across the conductive tab 508-1 of the auxiliary electrode 502 and the positive electrode 208 of the secondary battery 100 that is sufficient to drive carrier ions from the auxiliary electrode 502 to the positive electrode 208. In some implementations, the onset of transfer of carrier ions from the auxiliary electrode 502 to the positive electrode 208 of the secondary battery 100 may commence simultaneously with onset of the transfer of carrier ions from the positive electrode 208 to the negative electrode 209 of the secondary battery 100. In some implementations, the rate of transfer of carrier ions from the positive electrode 208 to the negative electrode 209 of the secondary battery 100 is greater than or equal to the rate of transfer of carrier ions from the auxiliary electrode 502 to the positive electrode 208 of the secondary battery 100, such that a good overall rate of transfer of carrier ions from the auxiliary electrode 502 to the negative electrode 209 of the secondary battery 100 via the positive electrode 208 can be maintained. That is, the relative rates of transfer between the positive electrode 208 and the negative electrode 209 of the secondary battery 100, and the auxiliary electrode 502 and the positive electrode 208, may be maintained such that the overall capacity of the positive electrode 208 for additional carrier ions is not exceeded. The positive electrode 208 may thus be maintained in a state where it has the ability to accept new carrier ions from the auxiliary electrode 502, which may allow for subsequent transfer of carrier ions to the negative electrode 209 of the secondary battery 100.

[0253] In some implementations, without being limited by any particular theory, the carrier ions are transferred from the auxiliary electrode 502 to the positive electrode 208 of the secondary battery 100 as a part of the replenishment of the negative electrode 209 of the secondary battery 100 (as opposed to transferring from the auxiliary electrode 502 directly to the negative electrode 209 of the secondary battery), because the positive electrode 208 may be capable of more uniformly accepting carrier ions across the surface thereof, thus allowing the carrier ionsAttorney Docket No. ENX-0160.WOto more uniformly participate in the transfer thereof between the positive electrode 208 and the negative electrode 209 of the secondary battery 100.

[0254] After the buffer process is performed on the secondary battery 100 utilizing the buffer system 500, the auxiliary electrode 502 may be removed from the buffer system 500 in order to improve the energy density of the secondary battery 100 in its final form. In some implementations, after the buffer process, the carrier ion supply layers 706 (see Fig. 7) may have been removed from the conductive layer 704, having been electrochemically transferred to the secondary battery 100. Thus, the auxiliary electrode 502 may be superfluous at this point. To remove the auxiliary electrode 502 from the enclosure 504 after the buffer process is performed, the enclosure layers 510, 511 of the enclosure may be cut along cut lines 1702, illustrated in Fig. 17 as solid lines, allowing the enclosure layers 510, 511 to be peeled back proximate to the auxiliary electrode 502. The auxiliary electrode 502 is removed from the enclosure 504 of the buffer system 500, while the secondary battery 100 remains within the pouch 514 (see Fig. 12). The enclosure layers 510, 511 may then be re-sealed along a final sealing line 1704 illustrated as dashed lines to form the enclosure 504 in its final form prior to placing the secondary battery 100 in service. This re-seal may be performed using any of the previously described processes for sealing the first enclosure layer 510 and the second enclosure layer 511 together.

[0255] Fig. 18 is a flow chart of a method 1800 of pre-lithiating a secondary battery with carrier ions using an auxiliary electrode of an example embodiment, and Figs. 19-21 are flow charts depicting additional details of the method 1800. The method 1800 will be described with respect to the secondary battery 100, the buffer system 500, and the auxiliary electrode 502 of Figs. 1-17, although the method 1800 may apply to other systems, not shown. The steps of the method 1800 are not all inclusive, and the method 1800 may include other steps, not shown. Further, the steps of the method 1800 may be performed in an alternate order.

[0256] In some implementations, the secondary battery 100 (see Fig. 1) has major surfaces 126, 127 that oppose each other, and the electrical terminals 124, 125. The electrical terminals 124, 125 are coupled to one of the positive electrode 208 of the secondary battery 100 (e.g., the population of the cathode structures 206 in the secondary battery 100, as depicted in Fig. 2) and the negative electrode 209 of the secondary battery 100 (e.g., the population of the anode structures 207 in the secondary battery 100, as depicted in Fig. 2). The secondary battery 100 comprises the microporous separator layer 108 (see Fig. 2) between the negative electrode 209 and the positive electrode 208 that is permeated with an electrolyte in ionic contact with the negative electrode 209 and the positive electrode 208. The negative electrode 209 comprisesAttorney Docket No. ENX-016Q.WOthe anodically active material 104, such as silicon or an alloy thereof, having a coulombic capacity for the carrier ions. The positive electrode 208 comprises the cathodically active material 106, having a coulombic capacity for the carrier ions, with a negative electrode 209 coulombic capacity exceeding a positive electrode 208 coulombic capacity.

[0257] The auxiliary electrode 502 (see Fig. 6) is placed in contact with the major surfaces 126, 127 of the secondary battery 100 to form the auxiliary subassembly 516, where the auxiliary electrode 502 includes the electrically conductive layer 704, the carrier ion supply layers 706 disposed on the conductive layer 704 that are proximate to the major surfaces 126, 127 of the secondary battery 100, the separator 702 disposed between the carrier ion supply layers 706 and the major surfaces 126, 127 of the secondary battery, and the electrically conductive tab 508 coupled to the conductive layer 704 (see step 1802 of Fig. 18, and Figs. 12-15).

[0258] The auxiliary subassembly 516 is installed in the enclosure 504, where the electrical terminals 124, 125 of the secondary battery 100 and the electrically conductive tab 508 of the auxiliary electrode 502 electrically extend from the perimeter 506 of enclosure 504 (see step 1804, and Fig. 16).

[0259] Carrier ions are transferred from the positive electrode 208 of the secondary battery 100 to the negative electrode 209 of the secondary battery 100 to at least partially charge the secondary battery 100 by applying a potential voltage across the electrical terminals 124, 125 (see step 1806). Charging may be discontinued when the positive electrode 208 of the secondary battery 100 reaches its the end-of-charge design voltage. During the initial charging cycle, SEI may form on the internal structural surfaces of the negative electrode 209 of the secondary battery 100.

[0260] To compensate for the loss of carrier ions to SEI, and to further provide additional carrier ions to mitigate the long term secondary reactions during cycling where carrier ions are lost due to side reactions, carrier ions are transferred from the carrier ion supply layers 706 of the auxiliary electrode 502 to the positive electrode 208 and / or the negative electrode 209 of the secondary battery 100 by applying a potential voltage across the electrically conductive tab 508 of the auxiliary electrode 502 and one or more of the electrical terminals 124, 125 of the secondary battery 100 (see step 1808, Fig. 16). In some implementations, this carrier ion buffer process transfers carrier ions from the carrier ion supply layers 706 of the auxiliary electrode 502 into each of the first major surface 126 of the secondary battery 100 and the second major surface 127 of the secondary battery 100 (see Fig. 15). In some implementations, transferring carrier ions to the secondary battery 100 from both of the major surfaces 126, 127 of the secondary battery 100, as depicted in Fig. 15, provides a technical benefit of distributing theAttorney Docket No. ENX-016Q.WOforces generated by anode and / or cathode swelling more equally across the casing 116 of the secondary battery 100 as more carrier ions are loaded into the cathode and / or the anode of the secondary battery 100.

[0261] In some implementations, the amount of carrier ions transferred from the auxiliary electrode 502 to the secondary battery 100 is about 50% of the reversable columbic capacity of the positive electrode 208 of the secondary battery 100. In some implementations, the amount of carrier ions transferred from the auxiliary electrode 502 to the secondary battery 100 is about 55%, about 60%, about 65%, about 70%, about 75%, about 80%, about 85%, about 90%, about 95%, or about 100% of the reversable columbic capacity of the positive electrode 208 of the secondary battery 100. In some implementations, the amount of carrier ions transferred from the auxiliary electrode 502 to the secondary battery 100 lies in a range of values of about 1% to about 100% of the reversable columbic capacity of the positive electrode 208 of the secondary battery 100. In some implementations, the negative electrode 209 of the secondary battery 100 has about 170% of the reversable columbic capacity of the positive electrode 208 of the secondary battery 100 stored as carrier ions when the secondary battery 100 is charged, and about 70% of the reversable columbic capacity of the positive electrode 208 of the secondary battery 100 stored as carrier ions when the secondary battery 100 is discharged. An excess of carrier ions at the negative electrode 209 of the secondary battery 100 provided during the buffer process provides a technical benefit of mitigating the loss of carrier ions at the secondary battery 100 due to SEI at initial formation. Further, an excess of carrier ions at the negative electrode 209 of the secondary battery 100 provided during the buffer process provides a technical benefit of mitigating the loss of carrier ions at the secondary battery 100 due to side reactions that deplete carrier ions in the secondary battery 100 as the secondary battery 100 is cycled during use, which reduces the capacity loss of the secondary battery 100 overtime.

[0262] In some implementations, transferring carrier ions from the auxiliary electrode 502 to the secondary battery 100 may occur concurrently with an initial formation of the secondary battery 100 (e.g., during the first charge of the secondary battery 100), and / or during a subsequent charge of the secondary battery 100 after initial formation. In some implementations, carrier ions are transferred from the positive electrode 208 of the secondary battery 100 to the negative electrode 209 of the secondary battery 100. Concurrently with or based on a temporal delay or a temporal pattern, carrier ions are transferred from the auxiliary electrode 502 to the positive electrode 208 and / or the negative electrode 209 of the secondary battery 100.

[0263] Carrier ions are again transferred from the positive electrode 208 of the secondary battery 100 to the negative electrode 209 of the secondary battery 100 to charge the secondaryAttorney Docket No. ENX-0160.WObattery 100 by applying a potential voltage across the electrical terminals 124, 125 of the secondary battery 100 until the negative electrode 209 has greater than 100% of the positive electrode 208 coulombic capacity stored as the carrier ions (see step 1810).

[0264] In some implementations, the positive electrode 208 may be replenished with carrier ions by simultaneously transferring carrier ions from the auxiliary electrode 502 to the positive electrode 208 of the secondary battery 100, while also transferring carrier ions from the positive electrode 208 of the secondary battery 100 to the negative electrode 209 of the secondary battery 100. In Fig. 6, a voltage is applied across the electrical terminals 124, 125 of the secondary battery 100, to drive carrier ions from the positive electrode 208 to the negative electrode 209 of the secondary battery 100. While the carrier ions are being transferred from the positive electrode 208 to the negative electrode 209, a voltage is applied across the conductive tab 508-1 of the auxiliary electrode 502 and the positive electrode 208 of secondary battery 100 to drive carrier ions from the auxiliary electrode 502 to the positive electrode 208 of the secondary battery 100. Thus, carrier ions are transferred from the auxiliary electrode 502 to the positive electrode 208 of the secondary battery 100 at the same time that carrier ions are being transferred from the positive electrode 208 to the negative electrode 209 of the secondary battery 100. That is, a voltage is maintained across the positive electrode 208 and the negative electrode 209 of the secondary battery 100 that is sufficient to drive carrier ions from the positive electrode 208 to the negative electrode 209 of the secondary battery 100, at the same time that a voltage is maintained across the conductive tab 508-1 of the auxiliary electrode 502 and the positive electrode 208 of the secondary battery 100 that is sufficient to drive carrier ions from the auxiliary electrode 502 to the positive electrode 208. In some implementations, the onset of transfer of carrier ions from the auxiliary electrode 502 to the positive electrode 208 of the secondary battery 100 may commence simultaneously with onset of the transfer of carrier ions from the positive electrode 208 to the negative electrode 209 of the secondary battery 100. In some implementations, the rate of transfer of carrier ions from the positive electrode 208 to the negative electrode 209 of the secondary battery 100 is greater than or equal to the rate of transfer of carrier ions from the auxiliary electrode 502 to the positive electrode 208 of the secondary battery 100, such that a good overall rate of transfer of carrier ions from the auxiliary electrode 502 to the negative electrode 209 of the secondary battery 100 via the positive electrode 208 can be maintained. That is, the relative rates of transfer between the positive electrode 208 and the negative electrode 209 of the secondary battery 100, and the auxiliary electrode 502 and the positive electrode 208, may be maintained such that the overall capacity of the positive electrode 208 for additional carrier ions is not exceeded. The positive electrodeAttorney Docket No. ENX-016Q.WO208 may thus be maintained in a state where it has the ability to accept new carrier ions from the auxiliary electrode 502, which may allow for subsequent transfer of carrier ions to the negative electrode 209 of the secondary battery 100.

[0265] In some implementations, without being limited by any particular theory, the carrier ions are transferred from the auxiliary electrode 502 to the positive electrode 208 of secondary battery 100 as a part of the replenishment of the negative electrode 209 of the secondary battery 100 (as opposed to transferring from the auxiliary electrode 502 directly to the negative electrode 209 of the secondary battery), because the positive electrode 208 may be capable of more uniformly accepting carrier ions across the surface thereof, thus allowing the carrier ions to more uniformly participate in the transfer thereof between the positive electrode 208 and the negative electrode 209 of the secondary battery 100.

[0266] In some implementations, of the method 1800, the enclosure 504 is opened (see step 1902 of Fig. 19), and the auxiliary electrode 502 is removed from the enclosure 504 (see step 1904). In response to removing the auxiliary electrode 502 from the enclosure 504, the enclosure is resealed into its final form to encapsulate the secondary battery 100 for use (see step 1906).

[0267] In some implementations, although installing the auxiliary subassembly 516 in the enclosure 504 as previously described with respect to step 1804 detailed above, comprises installing the auxiliary subassembly 516 on the first enclosure layer 510 (see step 2002 of Fig.20). The second enclosure layer 511 is installed on the first enclosure layer 510 (see step 2004), and the first enclosure layer 510 and the second enclosure layer 511 are sealed together along the sealing line 1602 to form the enclosure 504 (see step 2006).

[0268] The enclosure layers 510, 511 may be sealed along the sealing line 1602 (see Fig. 16) by welding, heat sealing, adhesive, combinations thereof, or the like. In some implementations, the enclosure layers 510, 511 may be sealed along three sides of the sealing line 1602 creating a pocket therein. In some implementations, the secondary battery 100 may be placed within the pocket, and the final edge of the sealing line 1602 is subsequently sealed. In some implementations, the sealing line 1602 is sealed using a hot press, that applies a controlled temperature and pressure to the sealing line 1602 causing the enclosure layers 510, 511 to adhere or fuse together along the sealing line 1602. In some implementations, a vacuum is applied to the secondary battery 100 during the sealing process to evacuate any excess volume occupied by air or other gas. The time for which the sealing line 1602 is subject to the hot press may be controlled and is dependent upon the materials selected for the enclosure layers 510, 511. Once sealed over the secondary battery 100, the sealed enclosure layers 510, 511 formAttorney Docket No. ENX-0160.WOthe buffer system 500. Upon sealing, the buffer system 500 is liquid tight and / or air-tight, depending on the desired application. The electrical terminals 124, 125 of the secondary battery 100 and the conductive tab 508 remain exposed and are not covered by the enclosure layers 510, 511.

[0269] In some implementations where the first enclosure layer 510 includes the pouch 514, installing the auxiliary subassembly 516 within the enclosure 504 initially comprises placing the auxiliary subassembly 516 within the pouch 514 (see step 2102 of Fig. 21). In some implementations, an electrolyte is added to the pouch 514 (e.g., either before or after installing the auxiliary subassembly 516 in the pouch 514), with the enclosure 504 formed subsequent thereto by sealing the first enclosure layer 510 and the second enclosure layer 511 together along the sealing line 1602.

[0270] In some embodiments, the energy manipulation device comprises an enclosure, e.g., a housing. The battery enclosure may be a (e.g., flexible) pouch. The battery enclosure may be flexible or rigid. The battery enclosure may have a rigid portion and / or a flexible portion. The battery may be a (e.g., rigid) can. The battery enclosure may comprise a first enclosure portion coupled with a second enclosure portion. The first enclosure portion and / or the second enclosure portion, may comprise a cavity shaped to hold the cell assembly. The cavity may form a recess, e.g., relative to edges of the cavity. The second enclosure portion may be a lid or a cover. Coupling of the enclosure portions with each other may occur around a perimeter of the each of the enclosure portions. The coupling of the enclosure portions may generate a sealed enclosure, e.g., a sealed pouch. The sealing may be fluid tight such as liquid tight or gas tight. The sealing may be debris tight, such as sealing a particulate material in the enclosure and / or not allowing a particulate material to ingress into the enclosure interior. The fluid tight sealing may hinder exchange of gaseous material between an ambient atmosphere external to the enclosure, and an interior of the enclosure. The gaseous material may comprise humidity, oxygen, carbon dioxide, carbon monoxide, methane, ethane, hydrogen sulfide, or any combination thereof. The liquid material may comprise water, electrolyte mixture, other organic liquid, or any combination thereof. The sealing may comprise a hermetic seal. The battery enclosure may comprise a central body. The central body may be configured to house the cell assembly. The central body may be of a shape, or adopt a shape, similar to the cell assembly, e.g., to hold the cell assembly. The enclosure may comprise an extension. The extension may extend from the central body. The extension may comprise a seal, e.g., where the first and second enclosure layers are coupled. The seal may be generated through heat sealing, pressure sealing, addition of an adhesive, or any combination thereof. The sealing may hinder aAttorney Docket No. ENX-016Q.WOreactive species to enter the interior of the enclosure. The reactive species may be any of the ones disclosed herein. The seal may isolate the ambient environment from an internal environment of the enclosure. The extension may comprise one or more flaps. The central body may have at least one FLS corresponding to the respective FLS of the cell assembly. The central body may have a height corresponding to the height of the cell assembly. The central body may have a width corresponding to a width of the cell assembly. The central body may have a length corresponding to the length of the cell assembly. Corresponding to may increase the FLS of the cell assembly at least by thickness of the enclosure material. The extension may extend from a periphery of the cell assembly and / or from the central body of the battery enclosure. The flaps may be folded along fold lines. The flaps may be folded along fold lines having a vectorial component along the height direction, e.g., along the height direction. The flaps may be folded towards sides of the central body. Each of the flaps may be folded toward a respective side of the central body. The flaps may be folded into contact with the sides of the central body, e.g., using an adhesive such as a thermosetting material and / or a tacky material.

[0271] In some embodiments, the enclosure comprises one or more portions. The enclosure material may comprise a multi-layer material. The multi-layer material may comprise the layer(s). The multi-layer material may comprise a combination of organic layers and barrier (e.g., metallic) layer(s), configured for use in the enclosure. An organic layer may comprise a polymer, a resin, a plurality of types thereof, copolymers thereof, a mixture thereof, or any other combination thereof. The organic layers may comprise a first and second organic layer, e.g., first and second layers of the layerwise material. At least one organic layer of the layerwise structure may comprise polyamide (e.g., nylon), polypropylene, polyphthalamide, polyethylene, polyethylene terephthalate, polybutylene terephthalate, polyvinylidene fluoride, polyimide, polyester, polycarbonate, polyvinylidene chloride, any plurality of types thereof, or any combination thereof. The organic layers may facilitate mechanical robustness, puncture resistance, scuff resistance, a heat-seal ability, or any combination thereof, e.g., of the enclosure. The organic layers may comprise primers, tie layers, adhesives, lacquer layers, heatseal coatings, polyurethane-based adhesives, epoxy-based adhesives, acrylic-based adhesives, any plurality of types thereof, or any combination thereof. Heat-seal coatings may allow for a heat-seal ability. The heat-seal coatings may comprise polyolefin-based adhesives such as maleic-anhydride-grafted polyolefins. The organic layers may be configured to promote adhesion between similar materials and / or dissimilar materials. The organic layers may tune the seal strength and / or sealing initiation temperature. The barrier layer may comprise a metal, high-barrier organic, or any combination thereof. The barrier layer may comprise a compositeAttorney Docket No. ENX-016Q.WOmaterial, or a non-composite material. The barrier material may comprise an elemental metal, a metal alloy, any plurality of types thereof, or any combination thereof. The barrier material may comprise aluminum, an aluminum alloy, steel, a steel alloy, nickel, copper, ethylene-vinyl alcohol (EVOH), polyvinylidene chloride (PVDC), or any combination thereof. The barrier layer may be configured to provide a moisture barrier, oxygen barrier, light barrier functionality, or any combination thereof.

[0272] In some embodiments, the enclosure (e.g., pouch) of the energy manipulation device comprises an extension extending from the periphery of the central body of the enclosure. The extension may comprise one or more flaps formed during the sealing process of the enclosure. The flaps may result from the joining of the first enclosure layer and the second enclosure layer along a sealing line at the periphery of the central body. The first enclosure layer and the second enclosure layer may be joined by heat sealing, welding, application of an adhesive, or any combination thereof. The sealing process may produce flaps along one or more sides of the central body. The sealing process may produce flaps along three sides of the pouch. The sealing process may produce flaps along four sides of the pouch. The sealing process may produce flaps along three sides and a terrace side from which the electrode terminal tab and the counter-electrode terminal tab extend. The flaps may extend outward from the central body in a direction substantially perpendicular to the height direction of the central body. The flaps may be folded towards the respective sides of the central body. The flaps may be folded along fold lines having a vectorial component along the direction of height, such that a face of each of the flaps lies substantially flush against the respective sides of the central body. An adhesive may be applied between the folded flap and the respective side of the central body to secure the flap in the folded position. The adhesive may comprise double-sided tape, a paste, a heat-activated adhesive, a pressure-sensitive adhesive, a thermoplastic adhesive, an epoxy, an acrylic, a polyimide-based adhesive, any plurality of types thereof, or any combination thereof. In some implementations, folding of the flaps may create protruding corner portions, sometimes referred to as "bat ear" flaps, at the corners of the central body. The bat ear flaps may subsequently be folded along the faces of the central body. The folding may reduce the overall footprint of the device. The folding may increase the energy density of the device.

[0273] In some embodiments, the extension of the enclosure is trimmed after sealing. The trimming may reduce the overall footprint of the energy manipulation device, e.g., compared to a non-trimmed device. The trimming may increase the energy density of the device, e.g., by minimizing excess enclosure material that does not contribute to housing the electrode assembly. The trimming may be performed by a compatible cutting technique, includingAttorney Docket No. ENX-016Q.WOmechanical cutting, chemical cutting, and / or non-mechanical physical cutting. Mechanical cutting may comprise a blade, die cutting, rotary cutting, or reciprocal cutting. Non-mechanical physical cutting may comprise a laser, e.g., using spallation, ablation, melting, or any combination thereof. The trimming may comprise fluid jet cutting. The trimming may be performed before, during, or after folding of the flaps towards the sides of the central body. In some implementations, the trimming step may also be applied to the electrode terminal tab and / or the counter-electrode terminal tab. The trimming of the electrode tab and / or counterelectrode tab may shorten the tabs. The shortened tabs may allow for the device to conform to a battery pack system design and / or implementation into an end user device. Trimming of the enclosure and / or the tabs, may reduce the footprint of the device.

[0274] In some embodiments, the enclosure (e.g., pouch) comprises a plurality of flaps. The flaps may be an extension of the enclosure from the central body of the enclosure, e.g., as disclosed herein. The flaps may comprise a multi-layer material. The flaps may be trimmed. The trimming may be performed by mechanical cutting and / or optical cutting (e.g., laser cutting). The trimming may comprise die cutting, rotary cutting, reciprocal cutting, laser cutting, fluid jet cutting, or any combination thereof. The trimming may be performed by mechanical cutting, chemical cutting, non-mechanical physical cutting, or any combination thereof. The chemical cutting may comprise corrosion, e.g., using acid. The mechanical cutting may comprise a blade, e.g., of a knife. The non-mechanical physical cutting may comprise a laser, e.g., using spallation, ablation, melting, or any combination thereof. The trimming may increase the energy density of the energy manipulation device, e.g., device. The trimming may reduce the overall volume of the device.

[0275] %%ln some embodiments, the trimming of the extension generates an exposed edge of the enclosure, e.g., exposed edge of the layers constituting the enclosure material. The exposed edge may be a cut edge resulting from the trimming operation. The cut edge may be a mechanically cut edge, a laser cut edge, or a combination thereof. The exposed edge may comprise a cross-sectional surface of the enclosure material layers. The cross-section surface (e.g., edge) may include cross-sections of metallic layer(s), nonmetallic (e.g., polymeric) layers, or any combination thereof (e.g., laminate), of the enclosure material. The exposed edge may present a cross-sectional face of the multi-layer enclosure material (e.g., laminate) along any portion of the trimmed side extension of the central body, e.g., along three sides (e.g., faces) corresponding to trimmed flaps and / or along the face corresponding to the terrace comprising the terminal tabs and from which the terminal tabs emerge. The exposed edge of the enclosure material may extend along one or more lateral sides of the enclosure, longitudinal sides of theAttorney Docket No. ENX-016Q.WOenclosure, or any combination thereof. The exposed edge may extend (e.g., substantially) along the entire perimeter of the enclosure. The exposed edge may be located proximate to the electrode terminal tab and / or to the counter-electrode terminal tab. The exposed edge may be located at the side (e.g., face) of the enclosure from which the terminal tabs extend (e.g., from the terrace).

[0276] In some embodiments, the exposed edge comprises a multi-layer cross section corresponding to the multi-layer material of the enclosure material. The exposed edge may comprise at least one metallic layer. The exposed edge may comprise additional polymer layers. The at least one metallic layer may be positioned between two polymeric layers in the cross-section of the exposed edge, e.g., in a sandwich configuration. The at least one metallic layer may comprise an elemental metal, a metal alloy, a metallic film, or any combination thereof. The at least one metallic layer may comprise aluminum, an aluminum alloy, steel, a steel alloy, nickel, copper, or any combination thereof. The at least one metallic layer may be electrically conductive. The exposed edge may comprise an electrically conductive material. The electrical conductivity may be attributed to one or more layers of the pouch. The electrical conductivity may be attributed to a metal, a metal alloy, a metallic layer, or a combination thereof. The electrically conductive material may allow for an unwanted distribution of electrical energy, e.g., from the device to other components of an end user device, or from other components of an end user device to the device. The at least one polymeric layer may comprise polyamide (e.g., nylon), polypropylene, polyethylene, polyethylene terephthalate, polyimide, polyester, or any combination thereof. The polymeric layers of the exposed edge may have diminished protective capability in the cross-sectional cut region as compared to the intact polymeric layers on the faces of the enclosure, e.g., because the polymeric layers are terminated at the cut edge rather than encapsulating the metallic layer on all sides.

[0277] In some embodiments, the exposed edge of the enclosure presents a risk of adverse electrical interaction. The adverse electrical interaction may be between the enclosure material and the ambient environment, and / or other components of the device. The adverse electrical interaction may result in shorting and / or corrosion, e.g., between the electrode and counterelectrode terminal tabs. The adverse interaction may be between the pouch and other components of an end-user device, e.g., such as electrical components in a cell phone. The adverse electrical interaction may result in a lower lifespan of the device. The exposed edge of the enclosure may present a risk of adverse chemical interactions. The at least one metallic layer of the exposed edge may be reactive to one or more agents present in the ambient environment. The reactive agents may comprise water (e.g., moisture vapor), oxygen, hydrogenAttorney Docket No. ENX-016Q.WOsulfide, or any combination thereof. Reaction of the metallic layer with such reactive agents may cause material degradation, corrosion, oxidation, or any combination thereof overtime. The degradation may adversely affect the structural integrity and / or the electrochemical performance of the energy manipulation device, e.g., by compromising the hermetic seal of the enclosure. The degradation may weaken the mechanical structure of the enclosure material. The corrosion may introduce byproducts into the environment proximate to the device. In some implementations, the electrically conductive metallic layer of the exposed edge may come into electrical contact with the electrode terminal tab and / or the counter-electrode terminal tab of the device. Such contact may create an unintended electrical pathway, e.g., an electrical short circuit between the electrically conductive metallic layer and one or both of the terminal tabs. Additionally, the electrically conductive exposed edge may allow for an unwanted distribution of electrical energy from the device to other components of an end user system, or from other components of the end user system to the device, e.g., posing safety risks and / or performance degradation.

[0278] In some embodiments, the enclosure comprises a nonconductor. An electrical coupling (e.g., electrical shorting) can occur between a metallic layer of the enclosure and an electrical conductor coupled with the cell assembly such as an exposed portion of the terminal tab, e.g., on their mutual contact. The nonconductor may form an insulating barrier, e.g., between the metallic layer of the enclosure and another conductor such as a terminal tab. The insulation may be electrical, thermal, or any combination thereof. The insulation may provide shock absorption properties. The nonconductor can be disposed (a) along at least a region of the exposed edge of the enclosure, (b) along at least a region of the exposed terminal tabs, (c) between the exposed edge of the enclosure and the terminal tabs, or (d) any combination thereof. The nonconductor can (i) contact at least a region of the exposed edge of the enclosure, (ii) contact at least a region of the exposed terminal tabs, (iii) be otherwise disposed between the exposed edge of the enclosure and the terminal tabs to hinder (e.g., prevent) their mutual contact, or (iv) any combination thereof. In an example, the nonconductor covers the entire enclosure and a portion of the terminal tab prone to contact the enclosure, e.g., upon folding of the terrace and / or of the terminal tab. The nonconductor may cover at least a portion of the cross-sectional surface of the exposed edge, or a portion of it, e.g., prone to contact the terminal tab(s). The nonconductor may insulate at least a portion of the exposed edge of the enclosure, e.g., at least a portion of the conductive (e.g., metallic) layer of the enclosure. The nonconductor may insulate the exposed metallic layer of the enclosure material and / or any exposed polymeric layers of the enclosure material. The nonconductor may insulate the device from the ambientAttorney Docket No. ENX-016Q.WOenvironment The nonconductor may insulate the enclosure material from electrical contact with other components of the device and / or end user system. The nonconductor may wrap around an exposed edge of at least one side of the enclosure, e.g., at least two, or three, consecutive sides of the enclosure. Covering consecutive faces may constitute a wrapped configuration of the nonconductor. The at least one region may comprise at least one side of the enclosure comprising the exposed edge. The nonconductor may extend from a first face (e.g., side) of the enclosure comprising the exposed edge, over the exposed edge cross section, and onto a second face of the enclosure comprising the exposed edge. The nonconductor may wrap around three of the faces of the battery enclosure, e.g., excluding the terrace. The nonconductor may wrap around at least three faces of the battery enclosure comprising the expose edge, e.g., four consecutive faces of a rectangular prismatic enclosure. The nonconductor may wrap around the face types of the enclosure excluding a face type having the largest surface area among the faces of the enclosure. The enclosure may have 1, 2, or 3 face types, each face type having a different surface area. The first faced type may have the smallest surface area, the second face type may have a medium surface area, and the third face type may have the largest surface area, relative to each other. The nonconductor may be disposed at the second (medium) face type. The nonconductor may be excluded from the third (largest) face type. The nonconductor may be disposed in at least one face of the first (smallest) face type. The wrapped configuration of the nonconductor with respect to the faces of the enclosure, may provide continuous coverage of insulation, mechanical durability (e.g., retention) of the nonconductor on the exposed edge(s), reduced fabrication error, or any combination thereof. The mechanical durability may be during manufacturing and / or during the prescribed use of the device such as disclosed herein. The wrapped configuration may allow for electrical isolation of the device relative to nearby electrical components. The nonconductor may be disposed along the exposed edge portion continuously or along discrete segments of the exposed edge. The nonconductor may be applied along regions of the exposed edge that are particularly susceptible to electrical shorting, e.g., the regions adjacent to the electrode terminal tab and / or the counter-electrode terminal tab. The nonconductor may be disposed along regions of the exposed edge that correspond to folded flaps of the extension (e.g., terrace). The nonconductor may be disposed along three consecutive regions of the exposed edge corresponding to three consecutive sides of the central body. The nonconductor may be disposed (e.g., substantially) along the (e.g., entire) length of the exposed edge, e.g., along four consecutive faces of the central body comprising trimmed and / or folded enclosure material. The central body may adopt a prismatic shape, e.g., a rectangular prism. The nonconductor may extend along one or moreAttorney Docket No. ENX-016Q.WOlateral sides of the enclosure, the lateral sides including the exposed edge. The trimmed portion of the enclosure exposing the edge, may be folded onto the side of the enclosure such that the edge is disposed within a height of the side, or at or above the height of the side. In an example, the edge is disposed (e.g., substantially) at a middle of the height of the side. Fig. 23, 2315 shows an example in which the edge is (e.g., substantially) at a middle of the height of a side of the enclosure from which terminal tabs emerge. In an example, the edge is disposed (e.g., substantially) at the height of the side, e.g., such that the side reaches.

[0279] In some embodiments, the nonconductor electrically insulates the exposed edge of the enclosure, e.g., trimmed edges of the enclosure. The nonconductor may hinder (e.g., prevent) electrical contact between the electrically conductive metallic layer of the exposed edge and a peripheral component. A peripheral component may comprise the electrode terminal tab, the counter-electrode terminal tab, other device (e.g., in a battery pack and / or series), a housing of the end user device, component of an end user device, any plurality of types thereof, or any combination thereof. The nonconductor may physically, chemically, and / or electronically, insulate the exposed edge. The insulation of the exposed edge by the nonconductor may be at least in part by forming a barrier between the exposed metallic and / or organic layers of the enclosure, and the ambient environment including reactive species in the ambient environment such as disclosed herein. The nonconductor may reduce (e.g., prevent) ingress of reactive agents to the exposed metallic layer of the enclosure. The reactive agents may be any disclosed herein. The nonconductor may hinder harm (e.g., corrosion or other chemical reaction) with the enclosure, e.g., with the metallic layer of the enclosure. The nonconductor may be configured to insulate the electrode assembly from the ambient environment. The nonconductor may create a hermetic or semi-hermetic, seal at the exposed edge. The hermetic seal may prevent passage of particulate matter, moisture vapor, oxygen, liquid, other reactive agents from the external environment to the electrode assembly through the exposed edge. The seal may reduce the risk of the enclosure seal rupturing, e.g., by providing an additional insulation and / or cushioning. The nonconductor may extend the operational lifespan of the energy manipulation device, increases its durability, allow for more robust manufacturing process, allow of longer storage time, allow for long transit time, or any combination thereof. The nonconductor may reduce the risk of short circuit, e.g., during the prescribed lifetime of the device and / or during the prescribed operation of the device. The nonconductor may reduce the risk of corrosion-induced performance degradation and / or increase the safety of the energy manipulation device (e.g., battery).Attorney Docket No. ENX-016Q.WO

[0280] In some embodiments, the nonconductor comprises a seal. The nonconductor (e.g., sealing the exposed edge) may be distinct from the seal of the enclosure layers that are coupled together to generate the enclosure. The nonconductor may be distinct from the adhesive used to join the flaps to the pouch walls (e.g., central body). The nonconductor may be configured to apply an additional hermetic seal, electrical seal, and / or cushioning, e.g., to the electrode assembly. The nonconductor may provide an additional sealing to the exposed edge of the central body of the enclosure, e.g., by joining the first enclosure layer (e.g., comprising the cavity) to the second enclosure layer (e.g., comprising the lid) along edge of the enclosure to form the seal of the enclosure. The nonconductor seal may be formed by heat sealing, welding, adhesive bonding, or any combination thereof. The electrode terminal tab and the counterelectrode terminal tab may extend from the electrode assembly through the extension of the enclosure to the external environment of the enclosure, e.g., through the terrace side of the enclosure. The nonconductor seal may hinder (e.g., prevent) passage of the electrolyte from the interior of the enclosure to the ambient environment external to the enclosure. The nonconductor seal may hinder (e.g., prevent) ingress of reactive agents from the exterior environment to the enclosure through the nonconductor. The nonconductor may provide a secondary barrier at the trimmed cut edge of the enclosure extension comprising the enclosure seal. The adhesive securing the folded flaps to the respective sides of the central body, may comprise a material that is different from, or similar to, the nonconductor. The difference in adhesive material may optimize the respective adhesion and / or insulation functions of each material.

[0281] In some embodiments, the nonconductor comprises a tape. The tape may be sized and / or shaped, to conform to the respective face of the central body to which it adheres, and / or the profile of the exposed edge which it is designed to protect, e.g., and cover. The tape may comprise a single-sided tape, a double-sided tape, a band, any plurality of types thereof, or any combination thereof. The tape may be a single-sided tape. The tape may be applied such that an adhesive side contacts the enclosure surface adjacent to the exposed edge, and the adhesive carrier side form the tape’s exposed side. The tape may contact the enclosure on opposite sides of the exposed edge, e.g., along the enclosure height. A non-adhesive side of the tape (e.g., carrier of the adhesive) may face the external environment. The tape may provide the insulating (e.g., and sealing) function at the exposed edge. The tape may be single sided or double sided. A double-sided tape may be applied to bond dual-sections of a portion of a folded exposed edge, e.g., corner protrusions. A double-sided tape may be applied to secure the pouch with an end user device. The nonconductor may be applied to (e.g., opposing) faces ofAttorney Docket No. ENX-016Q.WOthe enclosure such as on either side of the exposed edge cross section, e.g., to improve mechanical retention of the tape. The...

Claims

Attorney Docket No. ENX-0160.WOCLAIMSWhat is claimed is:

1. A device for energy manipulation, the device comprising:an electrode assembly comprising an electrode separated from a counter-electrode by a gap, the electrode and counter electrode being stacked along a stacking axis; and(A) the electrode assembly has consecutive sides, the electrode being coupled with an electrode busbar, the electrode busbar being disposed along at least two of the consecutive sides,(B) the counter-electrode is coupled with a counter-electrode busbar, the counter-electrode busbar having a portion folded upon itself,(C) the electrode assembly being disposed in an enclosure comprising a conductive layer, the enclosure enclosing the electrodes assembly to generate a central body of the enclosure, the enclosure comprising flaps disposed at a periphery of the central body, the flaps collectively bordering and encircling the periphery of the enclosure along a cross section of the enclosure, each of the flaps having an exposed edge exposing a conductive edge of the conductive layer, at least one flap of the flaps contacting a side of the central body, the at least one flap being coupled with a nonconductor to insulate the exposed edge of the flap,(D) the electrode assembly being coupled with a terminal tab extending from the electrode assembly internal to the enclosure, to an ambient environment external to the enclosure, at least a portion of the terminal tab being coupled with the nonconductor to insulate the at least the portion of the terminal tab,(E) the device is coupled with the nonconductor to insulate the conductive edge of the enclosure from a portion of the terminal tab external to the enclosure, or(F) any combination of (A), (B), (C), (D), and (E).

2. The device of claim 1, wherein the electrode assembly has the consecutive sides, the electrode being coupled with the electrode busbar, the electrode busbar being disposed along the at least two of the consecutive sides; optionally wherein the electrode busbar is disposed along at least three of the consecutive sides; optionally wherein the electrode assembly has a shape of a rectangular prism; optionally wherein the consecutive sides are exclude a side type having the largest surface area among side types of the enclosure; optionally wherein the electrode busbar extends across a fundamental length scale (FLS) of one side of theAttorney Docket No. ENX-0160.WOconsecutive sides; optionally wherein the electrode busbar extends across the FLS of at most one side of the consecutive sides; optionally wherein the electrode busbar extends across a portion of the FLS of one side of the consecutive sides; optionally wherein the electrode busbar extends across a first FLS portion of one side of the consecutive sides, and extends across a second FLS portion of a second side of the consecutive sides; optionally wherein the electrode busbar extends across a first FLS portion of one side of the consecutive sides, and extends across a second FLS portion of a second side of the consecutive sides; optionally wherein the electrode busbar extends across a first FLS portion of one side of the consecutive sides, an FLS of a second side of the consecutive sides, and a second FLS portion of a third side of the consecutive sides;optionally wherein the consecutive sides comprise a first side shorter than a second side, and the nonconductor extends across a FLS of the second side and at least a consecutive portion of the first side; and optionally wherein the consecutive sides comprise a first side shorter than a second side, and the nonconductor extends across a FLS of the first side and at least an FLS portion of the second side.

3. The device of claim 1 , wherein the electrode assembly is coupled with the counterelectrode busbar, the counter-electrode busbar having the portion folded upon itself; and optionally wherein the counter-electrode busbar has the portion folded upon itself in a U-turn like shape; and optionally wherein the electrode busbar and a counter-electrode busbar overlap at least in part in a direction, the counter-electrode busbar being coupled with the electrode assembly, the electrode busbar having a polarity opposing that of the counter-electrode busbar; and optionally wherein the direction (i) is a stacking direction along the stacking axis, or (ii) is a lateral direction normal to the stacking direction.

4. The device of claim 1, wherein the nonconductor comprises a resin, a polymer, any plurality of types thereof, or any combination thereof; optionally wherein the nonconductor is a tape; optionally wherein the tape is a non-conductive tape; optionally wherein the nonconductor comprises a thermosetting material, a tacky material, a shrinkwrap, a foam, any plurality of types thereof, or any combination thereof; and optionally wherein the nonconductor comprises a transparent material, an opaque material, or any combination thereof.

5. The device of claim 1 , wherein the electrode assembly is disposed in the enclosure comprising the conductive layer, the enclosure enclosing the electrodes assembly to generate the central body of the enclosure, the enclosure comprising the flaps disposed at the periphery of the central body, the flaps collectively bordering and encircling the periphery of the enclosure along the cross section of the enclosure, each of the flaps having the exposed edge exposingAttorney Docket No. ENX-0160.WOthe conductive edge of the conductive layer, at least one flap of the flaps contacting the side of the central body, the at least one flap being coupled with the nonconductor to insulate the exposed edge of the flap; optionally wherein the nonconductor is a layer; optionally wherein the cross section is of a rectangular shape; optionally wherein insulation by the nonconductor comprises electrical insulation, thermal insulation, chemical insulation, physical insulation, or any combination thereof; and optionally wherein insulation by the nonconductor comprises electrical insulation.

6. The device of claim 3, wherein the flaps of sides of the central body of the enclosure encircling a first side type having the largest surface area, the sides constituting (a) all the sides around the first side type, or (b) all the sides around the first side type except for a second side of a second side type different from the first side type; and optionally wherein the electrode assembly is coupled with at least one terminal tab, and wherein the at least one terminal tab emerges from the enclosure at the second side.

7. The device of claim 1 , wherein the electrode assembly is coupled with the terminal tab extending from the electrode assembly internal to the enclosure, to an ambient environment external to the enclosure, at least the portion of the terminal tab being coupled with the nonconductor to insulate the at least the portion of the terminal tab; optionally wherein insulation by the nonconductor comprises electrical insulation, thermal insulation, chemical insulation, physical insulation, or any combination thereof; and optionally wherein insulation by the nonconductor comprises electrical insulation; optionally wherein the terminal tab is an electrode terminal tab coupled with the electrode, the counter-electrode being coupled with a counterelectrode terminal tab extending from the electrode assembly internal to the enclosure, to the ambient environment external to the enclosure, at least the portion of the counter-electrode terminal tab being coupled with the nonconductor to insulate the at least the portion of the counter-electrode terminal tab; and optionally wherein the counter-electrode terminal tab and the electrode terminal tab emerge from one side of the enclosure.

8. The device of claim 1 , wherein the device is coupled with the nonconductor to insulate the conductive edge of the enclosure from the portion of the terminal tab external to the enclosure; optionally wherein the nonconductor is disposed between the conductive edge of a flap and the terminal tab, the flap being of the flaps; optionally wherein the terminal tab is an electrode terminal tab coupled with the electrode, the nonconductor insulates the conductive edge of the enclosure from a portion of a counter-electrode terminal tab external to the enclosure, the counter-electrode being coupled with the counter-electrode terminal tab that extends from the electrode assembly internal to the enclosure, to an ambient environment external to theAttorney Docket No. ENX-016Q.WOenclosure, at least a portion of the counter-electrode terminal tab being coupled with the nonconductor to insulate the at least the portion of the counter-electrode terminal tab; optionally wherein insulation by the nonconductor comprises electrical insulation, thermal insulation, chemical insulation, physical insulation, or any combination thereof; and optionally wherein insulation by the nonconductor comprises electrical insulation.

9. The device of claim 1 , wherein the electrode assembly comprise unit cells, each of the unit cells comprising the electrode separated from the counter-electrode by the gap; optionally wherein the unit cells are stacked along the stacking axis; optionally wherein the unit cells are at least about 10, 50, 100, 150, 200, 250, or 300 unit cells; optionally wherein the electrode comprises an electrode current collector covered with electrode active material at opposing sides of the electrode current collector; optionally wherein the electrode comprises a counterelectrode current collector covered with counter-electrode active material at opposing sides of the counter-electrode current collector; optionally wherein the gap comprises a separator configured to allow charge carriers to pass therethrough; optionally wherein the electrode busbar is configured to electrically connect each of the electrode of the unit cells; and optionally wherein the counter-electrode busbar is configured to electrically connect each of the counterelectrodes of the units cells.

10. The device of claim 1, wherein the electrode comprises electrode active material comprising silicon; optionally wherein the electrode assembly is of a secondary battery; optionally wherein the device comprises charge carriers comprising alkali, alkali earth, or a combination thereof; and optionally wherein the charge carriers comprise lithium.

11. The device of claim 1 , wherein the conductive edge comprises at least one metallic layer; optionally wherein the conductive edge comprises at least one organic layer; optionally wherein the at least one metallic layer is positioned adjacent to one or more organic layers; optionally wherein the at least one metallic layer is positioned between at least two organic layers; optionally wherein the at least one metallic layer comprises an elemental metal, a metal alloy, a plurality of types thereof, or any combination thereof; optionally wherein the conductive layer is configured to conduct electricity and / or heat; optionally wherein the conductive layer is configured to conduct electricity; optionally wherein the conductive layer can undergo a reaction with a reactive species present in an ambient environment; optionally wherein the reaction leads to corrosion of the conductive layer; optionally wherein the conductive layer can electrically short on contact with the terminal tab; optionally wherein the reactive species causes material degradation, electrical short, or any combination thereof, when reacting (i) with the tab, (ii) with the conductive layer, or (iii) with the tab and with the conductive layer; optionally wherein theAttorney Docket No. ENX-0160.WOdegradation comprises corrosion; and optionally wherein the reactive species comprises water, oxygen, acid, or hydrogen sulfide.

12. The device of claim 1, wherein the conductive edge comprises a cut edge; and optionally wherein the cut edge is indicative of a mechanical cutting and / or laser cutting.

13. The device of claim 1, wherein a portion of the conductive edge comprises a region along one side of the central body; optionally wherein the nonconductor is disposed along at least two, or at least three regions of the conductive edge portion adjacent to respective sides of the central body; optionally wherein the regions are consecutive such that they border each other; optionally wherein the sides are consecutive such that they border each other; optionally wherein a region of the conductive edge comprises a perimeter of a seal of the enclosure, the flaps comprise the seal; optionally wherein the region of the conductive edge comprises a region adjacent to the terminal tab; optionally wherein the region of the conductive edge comprises discrete segments being separated from each other by a gap; optionally wherein the region of the conductive edge is of the flaps; optionally wherein the nonconductor extends along one or more sides of the central body having a surface area smaller than a side of the central body having the largest surface area; optionally wherein the nonconductor extends along all sides of the enclosure (a) other that a side type having the largest surface area and (b) other than a side having a flap that connects to a terrace side at an edge of the side, and is otherwise uncoupled with the terrace side of the central body, the terrace side having a surface area smaller than another side type of the central body having the largest surface area; optionally wherein the terrace side of the central body is of a type having the smallest surface area among side types of the central body; optionally wherein the nonconductor extends along sides of the enclosure different from the side type having the largest surface area; and optionally wherein the nonconductor extends along the enclosure, the enclosure including the conductive edge.

14. The device of claim 1 , wherein the busbar comprises at least two sections that are coupled together; optionally wherein coupling of the two sections together comprise welding, adhering, soldering, brazing, clinching, hemming, fastening, a plurality of types thereof, or any combination thereof; optionally wherein welding comprises laser welding, spot welding, or any combination thereof; optionally wherein adhering is at least in part using a conductive adhesive; and optionally wherein the fastening comprises a mechanical fastener comprising a screw, a bolt, a nut, a riven, a clamp, a snap fit, any plurality of types thereof, or any combination thereof.

15. The device of claim 1, wherein the nonconductor is disposed between the terminal tab and the conductive edge such that the nonconductor does not contact the terminal tab, the nonconductor comprising (a) a first portion contacting at least a portion of the terminal tab, (b) aAttorney Docket No. ENX-0160.WOsecond portion contacting at least a portion of the conductive edge on the side of the enclosure from which the terminal tab emerges, (c) a third portion disposed in an intermediate region between the terminal tab and the conductive edge coupled with a side of the central body from which the terminal tab emerges out of the enclosure, or (d) any combination of (a), (b), and (c).

16. The device of claim 1 , wherein the nonconductor is configured to seal from an ambient environment; optionally wherein the seal comprises a hermetic seal; and optionally wherein the seal comprises a liquid tight seal, a solid tight seal, a gel-tight seal, a gas tight seal, or any combination thereof.

17. The device of claim 1, wherein the nonconductor comprises tape; optionally wherein the tape comprises a single-sided tape, double-sided tape, a flexible tape, or any combination thereof; optionally wherein the tape includes a material comprising a polymer, a resin, an organic, a composite, a silicon-based material, an elastomeric, a thermoplastic, a plurality of types thereof, or any combination thereof; optionally wherein the silicon-based material comprises a silicon elastomer, a silicon resin, a siloxane polymer (polysiloxane), any plurality of types thereof, or any combination thereof; optionally wherein the material of the tap comprises a polyester, an acrylic, any plurality of types thereof, or any combination thereof; optionally wherein the material of the tape comprises a water-based material, an organic solvent based material, a hot-melt material, an electromagnetic curable material, a pressure sensitive material, a plurality of types thereof, or any combination thereof; optionally wherein the polyester comprises a polyethylene terephthalate, polybutylene terephthalate, a polyethylene naphtholate, any plurality of types thereof, or any combination thereof; and optionally wherein the tape comprises a polyimide, polyethylene, a polypropylene, any plurality of types thereof, or any combination thereof.

18. The device of claim 1, wherein the nonconductor comprises a glue; optionally wherein the glue comprises a heat-activated adhesive, a pressure-sensitive adhesive, an electromagnetic radiation activated adhesive, a thermoplastic adhesive, any plurality of types thereof, or any combination thereof; and optionally wherein the glue comprises an epoxy, an acrylic, a polyimide, any plurality of types thereof, or any combination thereof.

19. The device of claim 1, wherein the nonconductor comprises a photosensitive material; optionally wherein the photosensitive material is sensitive to ultraviolet radiation, infrared radiation, visible light, or any combination thereof; and optionally wherein the photosensitive material is sensitive to ultraviolet radiation.

20. The device of claim 1 , wherein the enclosure comprises an enclosure seal configured to seal the electrode assembly in the enclosure, the terminal tab extending from the electrodeAttorney Docket No. ENX-0160.WOassembly through the enclosure seal to an external environment of the enclosure; optionally wherein the enclosure seal is configured to couple two or more portions of the enclosure; optionally wherein the portions of the enclosure comprise a cup and a lid of the cup; optionally wherein coupling the lid and the cup generates the central body and the flaps; optionally wherein the flaps are trimmed to expose the conductive edge; optionally wherein the seal is a hermetic seal; optionally wherein the seal comprises an adhesive configured to adhere the cup with the lid; optionally wherein the seal is devoid of an adhesive configured to adhere the cup with the lid; optionally wherein the seal is indicative of the cup being coupled with the lid using heat and / or pressure; optionally wherein the seal is indicative of the cup being coupled with the lid at least in part by altering material properties of the cup and the lid, at least in part in a region of the seal; optionally wherein the seal is indicative of the cup being coupled with the lid at least in part using trimming; optionally wherein the trimming comprises one or more punching methodologies; optionally wherein the trimming comprises mechanical cutting, laser cutting, any plurality of types thereof, or any combination thereof; optionally wherein materials of the seal and of the nonconductor are different; optionally wherein different is at least in part by their chemical makeup, physical state, texture, or any combination thereof, at a given temperature and pressure; and optionally wherein the give temperature and pressure is at an ambient temperature of the ambient environment; and optionally wherein the given temperature is from about -20 Celsius (°C) to about 60°C.

21. The device of claim 1 , wherein the nonconductor acts to condition an impact before reaching the electrode assembly, the impact being exerted on the enclosure from conditions external to the enclosure; optionally wherein the conditions comprise physical impact, chemical impact, or any combination thereof; optionally wherein the physical impact comprises temperature change, excessive force on a location, or any combination thereof, the excessive force capable of damaging the enclosure, the temperature change capable of damaging the enclosure and / or damaging cell assembly; optionally wherein the temperature change is capable of causing a thermal runaway reaction in the cell assembly; optionally wherein the nonconductor comprises an elastic material; and optionally wherein the nonconductor comprises a cushion.

22. A method of using the device of any of claims 1 to 21 , the method comprising (a) providing the device and (b) using the device for the energy manipulation; and optionally wherein using the device comprises storing, transporting, servicing, upgrading, buffering, forming a passivation layer, and / or cycling the device between charge and discharge states of the cell assembly.Attorney Docket No. ENX-0160.WO23. An apparatus for the energy manipulation, the apparatus comprising one or more controllers configured to (a) operatively couple with the device of any of claims 1 to 21, and (b) direct one or more components to use, the one or more controllers being operatively coupled with the one or more components; optionally wherein use of the device comprises storing, transporting, servicing, upgrading, buffering, forming a passivation layer, and / or cycling the device between charge and discharge states of the cell assembly; optionally wherein the one or more controllers comprise, or are operatively coupled with, a communication system and / or comprise connection configured to couple with a power source; optionally wherein the connection is an electrical connection; and optionally wherein the power source is an electrical grid.

24. Non-transitory computer-readable program instructions physically inscribed on at least one media, the program instructions, when read by one or more processors operatively coupled with the device of any of claims 1 to 21 , cause the one or more processors to execute one or more operations for using the device for the energy manipulation; and optionally wherein using the device comprises storing, transporting, servicing, upgrading, buffering, forming a passivation layer, and / or cycling the device between charge and discharge states of the cell assembly.

25. A method of generating the device of any of claims 1 to 21 , the method comprising manufacturing the device; optionally wherein the manufacturing comprise adding the nonconductor to generate the device; and optionally wherein adding the nonconductor comprises coating, spraying, brushing, dipping, immersion, curing, temperature conditioning, applying pressure, applying a mask, additive manufacturing, any plurality of types thereof, or any combination thereof.

26. An apparatus for the energy manipulation, the apparatus comprising one or more controllers configured to (a) operatively couple with one or more components configured to manufacture the device of any of claims 1 to 21, and (b) direct the one or more components to execute one or more operations to manufacture the device; optionally wherein the one or more operations comprise adding the nonconductor to generate the device; optionally wherein adding the nonconductor comprises coating, spraying, brushing, dipping, immersion, curing, temperature conditioning, applying pressure, applying a mask, additive manufacturing, any plurality of types thereof, or any combination thereof; optionally wherein the one or more controllers comprise, or are operatively coupled with, a communication system and / or connection configured to couple with a power source; optionally wherein the connection is an electrical connection; and optionally wherein the power source is an electrical grid.Attorney Docket No. ENX-016Q.WO27. Non-transitory computer-readable program instructions physically inscribed on at least one media, the program instructions, when read by one or more processors operatively coupled with the device of any of claims 1 to 21 , cause the one or more processors to execute one or more operations for manufacturing the device for use in the energy manipulation; optionally wherein the one or more operations comprise adding the nonconductor to generate the device; and optionally wherein adding the nonconductor comprises coating, spraying, brushing, dipping, immersion, curing, temperature conditioning, applying pressure, applying a mask, additive manufacturing, any plurality of types thereof, or any combination thereof.

Images