Enovix Corporation

International Business Machines Corporation

Hitachi Global Storage Technologies Netherlands B.v.

Enovix Operations Inc.

Ashok Lahiri

Murali Ramasubramanian

Harrold Jones Rust, Iii

James D Wilcox

Nirav S Shah

Robert S Busacca

Bruno A Valdes

Robert M Spotnitz

John F Varni

Christopher J Spindt

Kim Han Lee

Richard J Contreras

Gardner Cameron Dales

Geoffrey Matthew Ho

Michael J Armstrong

Lynn Van Erden

Jeremie James Dalton

Laurie Jane Lauchlan

Gunther A Koblmiller

Brian E Brusca

Ken S Matsubayashi

Christopher G Castledine

Robert Keith Rosen

Kim Lester Fortunati

Vladimir K Dioumaev

Jeffrey Glenn Buck

Jonathan C Doan

Joshua David Winans

Neal Sarswat

Jason N Howard

Thomas John Schuerlein

Anthony Calcaterra

Robert A Cole

Neelam Singh

Benjamin L Cardozo

Edward Hin Pong Lee

Hong Xu

Eric James Lee

Miles E Beaven

Jeffery A Moss

David T Fouchard

Mustafa Pinarbasi

Bruno Michel

Richard Hsiao

Alexander Bietsch

Clinton David Snyder

Thomas Edward Dinan, Jr

John I Kim

Michael William Chaw

Mark Clinton Thurber

Michael T Andres

Daniel J Noelle

Robert M Spotniz

Benjamin J Cardozo

Markus Schmidt

Rainer Klaus Krause

Ian Robson McFadyen

Stefan Seifried

Robert F Kinchen

Wolfgang Egert

John S Thorne

Kang Yao

Christopher Castledine, Iii

Harold J Rust, Iii

Eva Urlaub

Michael E Andres

Rajeswari Chandrasekaran

Brett Kiger

Spencer Gore

A method includes stacking unit cells in a stacking direction. Each unit cell includes an electrode structure, a separator structure, and a counter-electrode structure. The electrode structure includes an electrode current collector and an electrode active material layer, and the counter-electrode structure includes a counter-electrode current collector and a counter-electrode active material layer. The electrode and counter-electrode structures extend in a longitudinal direction perpendicular to the stacking direction, and an end portion of the electrode current collector extends past the electrode active material and the separator structure in the longitudinal direction. The end portion of each electrode current collector is bent in a direction orthogonal to the longitudinal direction, an electrode busbar is positioned extending in the stacking direction with a surface adjacent the end portions, and heat and pressure are applied to the electrode busbar to adhere the end portions to the busbar through an adhesive layer.

Electrode assemblies including current limiters

A secondary battery is provided for cycling between a charged and a discharged state, the secondary battery including a battery enclosure, an electrode assembly, carrier ions, a non-aqueous liquid electrolyte within the battery enclosure, and a set of electrode constraints. The set of electrode constraints includes a primary constraint system having first and second primary growth constraints and at least one primary connecting member, the first and second primary growth constraints separated from each other in the longitudinal direction, wherein the primary constraint array restrains growth of the electrode assembly in the longitudinal direction such that any increase in the Feret diameter of the electrode assembly in the longitudinal direction over 20 consecutive cycles of the secondary battery is less than 20%. The set of electrode constraints further includes a secondary constraint system having first and second secondary growth constraints connected by at least one secondary connecting member, wherein the secondary constraint system at least partially restrains growth of the electrode assembly in a second direction upon cycling of the secondary battery.

Dimensional constraints for three-dimensional batteries

A energy storage device for cycling between a charged state and a discharged state, the energy storage device including an enclosure, an electrode assembly and a non-aqueous liquid electrolyte within the enclosure, and a constraint that maintains a pressure on the electrode assembly as the energy storage device is cycled between the charged and the discharged states.

Longitudinal constraints for energy storage devices

Secondary batteries and methods of manufacture thereof are provided. A secondary battery can comprise an electrode layer comprising a population of spacer structures comprising a material other than the electrode active material, wherein (a) the spacer population occupies a total volume within the electrode layer within the range of about 0.1% to about 35% of the volume, V, of the electrode layer, and (b) a member of the spacer population is located within each subvolume of the electrode layer comprising (i) at least 25% of the volume, V, of the electrode layer, and (ii) bounded on all sides by (aa) the unit cell portion of the electrode current collector, (bb) the separator layer, (cc) the top surface of the electrode layer, (dd) the bottom surface of the electrode layer, (ee) the first end surface of the electrode layer, and (ff) the second end surface of the electrode layer.

Electrode assembly, secondary battery, and method of manufacture

Various three-dimensional battery structures are disclosed, in certain embodiments comprising a battery enclosure and a first plurality of electrodes within the enclosure. The first plurality of electrodes includes a plurality of cathodes and a plurality of anodes. The first plurality of electrodes includes a second plurality of electrodes selected from the first plurality of electrodes. The three-dimensional battery includes a first structural layer within the battery enclosure. Each of the second plurality of electrodes protrudes from the first structural layer. The three-dimensional battery includes a plurality of electrical current-reducing devices within the enclosure. Each of the second plurality of electrodes is coupled to one of the plurality of current-reducing devices.

Three-dimensional battery having current-reducing devices corresponding to electrodes

An electrode structure for use in an energy storage device, the electrode structure comprising a population of electrodes, a population of counter-electrodes and an electrically insulating material layer separating members of the electrode population from members of the counter-electrode population, each member of the electrode population having a longitudinal axis Athat is surrounded by the electrically insulating separator layer.

Separators for three-dimensional batteries

Embodiments of secondary batteries having electrode assemblies are provided. A secondary battery can comprise an electrode assembly having a stacked series of layers, the stacked series of layers having an offset between electrode and counter-electrode layers in a unit cell member of the stacked series. A set of constraints can be provided with a primary constraint system with first and second primary growth constraints separated from each other in a longitudinal direction, and connected by at least one primary connecting member, and a secondary constraint system comprises first and second secondary growth constraints separated in a second direction and connected by members of the stacked series of layers. The primary constraint system may at least partially restrain growth of the electrode assembly in the longitudinal direction, and the secondary constraint system may at least partially restrain growth in the second direction that is orthogonal to the longitudinal direction.

Electrode assembly and secondary battery

Embodiments of a method for the preparation of an electrode assembly, include removing a population of negative electrode subunits from a negative electrode sheet, the negative electrode sheet comprising a negative electrode sheet edge margin and at least one negative electrode sheet weakened region that is internal to the negative electrode sheet edge margin, removing a population of separator layer subunits from a separator sheet, and removing a population of positive electrode subunits from a positive electrode sheet, the positive electrode sheet comprising a positive electrode edge margin and at least one positive electrode sheet weakened region that is internal to the positive electrode sheet edge margin, and stacking members of the negative electrode subunit population, the separator layer subunit population and the positive electrode subunit population in a stacking direction to form a stacked population of unit cells.

Electrode assembly manufacture and device

A process for delineating a population of electrode structures in a web includes laser ablating the web to form ablations in the web, each ablation being formed by removing a portion of an electrochemically active layer to thereby expose a portion of an electrically conductive layer. The process includes forming alignment features in the web that are formed at predetermined locations on the web. The process also includes laser machining the web to form weakened tear patterns in the web that delineate members of the electrode structure population, each of the delineated members being individually bounded, at least in part, by a member of the weakened tear patterns that is adapted to facilitate separation of delineated members, individually, from the web by an application of a force, the alignment features being used to aid in the formation of the weakened tear patterns.

Apparatus, systems and methods for the production of electrodes for use in batteries

A secondary battery for cycling between a charged and a discharged state, wherein a 2D map of the median vertical position of the first opposing vertical end surface of the electrode active material in the X-Z plane, along the length LE of the electrode active material layer, traces a first vertical end surface plot, EVP1, a 2D map of the median vertical position of the first opposing vertical end surface of the counter-electrode active material layer in the X-Z plane, along the length LC of the counter-electrode active material layer, traces a first vertical end surface plot, CEVP1, wherein for at least 60% of the length LC of the first counter-electrode active material layer (i) the absolute value of a separation distance, SZ1, between the plots EVP1 and CEVP1 measured in the vertical direction is 1000 μm≥|SZ1|≥5 μm.

Constrained electrode assembly

Secondary batteries and methods of manufacture thereof are provided. A secondary battery can comprise an offset between electrode and counter-electrode layers in a unit cell. Secondary batteries can be prepared by removing a population of negative electrode subunits from a negative electrode sheet, the negative electrode sheet comprising a negative electrode sheet edge margin and at least one negative electrode sheet weakened region that is internal to the negative electrode sheet edge margin, removing a population of separator layer subunits from a separator sheet, and removing a population of positive electrode subunits from a positive electrode sheet, the positive electrode sheet comprising a positive electrode edge margin and at least one positive electrode sheet weakened region that is internal to the positive electrode sheet edge margin, and stacking members of the negative electrode subunit population, the separator layer subunit population and the positive electrode subunit population.

An electrode structure for use in an energy storage device comprising a population of electrodes, a population of counter-electrodes and a microporous separator separating members of the electrode population from members of the counter-electrode population. Each member of the electrode population comprises an electrode active material layer and an electrode current conductor layer, and each member of the electrode population has a bottom, a top, a length L, a width Wand a height H, wherein the ratio of Lto each of Wand His at least 5:1, the ratio of Hto Wis between 0.4:1 and 1000:1, and the electrode current collector layer of each member of the electrode population has a length Lthat is measured in the same direction as and is at least 50% of length L.

Electrode structures for three-dimensional batteries

A method is provided for activating a secondary battery having a negative electrode, a positive electrode, and a microporous separator between the negative and positive electrodes permeated with carrier-ion containing electrolyte, the negative electrode having anodically active silicon or an alloy thereof. The method includes transferring carrier ions from the positive electrode to the negative electrode to at least partially charge the secondary battery, and transferring carrier ions from an auxiliary electrode to the positive electrode, to provide the secondary battery with a positive electrode end of discharge voltage Vand a negative electrode end of discharge so voltage Vwhen the cell is at a predefined Vvalue, the value of Vcorresponding to a voltage at which the state of charge of the positive electrode is at least 95% of its coulombic capacity and Vis at least 0.4 V (vs Li) but less than 0.9 V (vs Li).

Replenished negative electrodes for secondary batteries

A secondary battery for cycling between a charged and a discharged state is provided. The secondary battery has an electrode assembly having a population of anode structures, a population of cathode structures, and an electrically insulating microporous separator material. The electrode assembly also has a set of electrode constraints that at least partially restrains growth of the electrode assembly. Members of the anode structure population have a first cross-sectional area, Awhen the secondary battery is in the charged state and a second cross-sectional area, A, when the secondary battery is in the discharged state, and members of the cathode structure population have a first cross-sectional area, Cwhen the secondary battery is in the charged state and a second cross-sectional area, C, when the secondary battery is in the discharged state, where Ais greater than A, and Cis less than C.

Three-dimensional batteries with compressible cathodes

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Cupertino, CA, United States of America

Ashok Lahiri