Enovix Corporation

Enovix Operations Inc.

International Business Machines Corporation

Bruno A Valdes

Robert S Busacca

Murali Ramasubramanian

Ashok Lahiri

John F Varni

Kim Han Lee

Harrold Jones Rust, Iii

Richard J Contreras

Christopher J Spindt

James D Wilcox

Geoffrey Matthew Ho

Gardner Cameron Dales

Nirav S Shah

Lynn Van Erden

Jeremie James Dalton

Ken S Matsubayashi

Robert Keith Rosen

Kim Lester Fortunati

Anthony Calcaterra

Jeffrey Glenn Buck

Thomas John Schuerlein

Joshua David Winans

Neal Sarswat

Jason N Howard

Michael J Armstrong

Neelam Singh

Jonathan C Doan

Vladimir K Dioumaev

Benjamin L Cardozo

Gunther A Koblmiller

Robert F Kinchen

Miles E Beaven

Jeffery A Moss

Robert M Spotnitz

William H Chandler, Jr

Daniel J Noelle

Benjamin J Cardozo

Michael T Andres

Miles A M Kool

Michael Zung

Aditya Mandalam

Xavier Charles Lelong

Sonny Bell

Edward Joseph Pacheco

Buddy Chang

Michael E Andres

Ilya Dvoiris

James Moody

Harrold J Rust

Iii Harrold J Rust

Jason Newton Howard

Harrold Jones Rust Iii

A method for manufacturing a structure comprising and electrode assembly having a porous electrically insulating material, and first and second endplates, is provided. The electrode assembly comprises a population of unit cells stacked in series in a stacking direction, opposing first and second longitudinal end surfaces separated along the stacking direction. First and second endplates are separated in the stacking direction and overlie the first and second longitudinal end surfaces. According to embodiments of the structure, (i) each unit cell comprises an electrode structure, a counter-electrode structure, and an electrically insulating separator between the electrode and counter-electrode structures, (ii) the electrode structures, counter-electrode structures and electrically insulating separators within each unit cell have opposing first and second vertical end surfaces separated in a vertical direction, and (iii) the vertical direction is orthogonal to the stacking direction. The method comprises providing a porous electrically insulating material to the electrode assembly using a stencil.

Electrode assembly structure, secondary battery, and methods of manufacture

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

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 assembly includes an electrode assembly having mutually perpendicular transverse, longitudinal, and vertical axes corresponding to X, Y and Z axes, respectively. A constraint is disposed on an outer surface of the electrode assembly. At least one of the electrode assembly or constraint has a protrusion extending in an X-Y plane defined by the X and Y axes and having a first radius of curvature in the X-Y plane. A battery enclosure encloses the electrode assembly and the constraint. An enclosure protection layer is disposed over at least a portion of the protrusion and between the protrusion and the battery enclosure. The enclosure protection layer defines a second radius of curvature overlying the first radius of curvature in the X-Y plane. The second radius of curvature is greater than the first radius of curvature to thereby reduce the potential of the protrusion causing damage to the battery enclosure.

Protection layer for electrochemical batteries and systems and methods therefor

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

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 assembly for a secondary battery and method are provided. The electrode assembly comprises a population of unit cells and a constraint system. The electrode assembly comprises a population of electrode structures, a population of counter-electrode structures, and an electrically insulating separator material. The constraint system comprises (i) first and second primary growth constraints separated in the longitudinal direction, (ii) first and second connecting members separated in the vertical direction that connect the first and second primary growth constraints and a subset of the members of the electrode or counter-electrode population. The first and second connecting members are adhered to the subset by an electrically-insulating, thermoplastic, hot-melt adhesive having (i) a melting temperature in the range of 75° C. to 130° C., and (ii) a melt index value as measured according to ASTM D1238 in a range of at least 20 to no more than 350.

Three-dimensional batteries using constraint adhesive

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Sunnyvale, CA, United States of America

Bruno A Valdes