Enovix Corporation

Benjamin L Cardozo

Murali Ramasubramanian

Ashok Lahiri

Robert S Busacca

Bruno A Valdes

Kim Han Lee

Jeremie James Dalton

Anthony Calcaterra

Christopher J Spindt

John F Varni

Harrold Jones Rust, Iii

Lynn Van Erden

James D Wilcox

Nirav S Shah

Jason N Howard

Richard J Contreras

Michael J Armstrong

Gardner Cameron Dales

Geoffrey Matthew Ho

Ken S Matsubayashi

Robert Keith Rosen

Neelam Singh

Kim Lester Fortunati

Jeffrey Glenn Buck

Thomas John Schuerlein

Neal Sarswat

Jonathan C Doan

Joshua David Winans

Iii Harrold J Rust

Jason Newton Howard

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

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

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.

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Palo Alto, CA, United States of America

Benjamin L Cardozo