Patent Application
20230411792
The field of the disclosure relates generally to energy storage technology, such as battery technology. More specifically, the field of the disclosure relates to systems and methods for the assembly of energy storage systems, such as electrodes for use in secondary batteries, including lithium based batteries.
Lithium based secondary batteries have become desirable energy sources due to their comparatively high energy density, power and shelf life. Examples of lithium secondary batteries include non-aqueous batteries such as lithium-ion and lithium-polymer batteries.
Known energy storage devices, such as batteries, fuel cells and electrochemical capacitors, typically have two-dimensional laminar architectures, such as planar or spirally wound (i.e., jellyroll) laminate structures, where a surface area of each laminate is approximately equal to its geometric footprint (ignoring porosity and surface roughness).
Three-dimensional secondary batteries may provide increased capacity and longevity compared to laminar secondary batteries. The production of such three-dimensional secondary batteries, however, presents manufacturing and cost challenges. Precision manufacturing techniques used, to-date, can yield secondary batteries having improved cycle life but at the expense of productivity and cost of manufacturing. When known manufacturing techniques are sped up, however, an increased number of defects, loss of capacity and reduced longevity of the batteries can result.
Thus, it would be desirable to produce three-dimensional batteries while addressing the issues in the known art.
An embodiment includes a secondary battery for cycling between a charged state and a discharged state. The battery comprises an enclosure and an electrode assembly disposed within the enclosure, wherein the electrode assembly has mutually perpendicular transverse, longitudinal, and vertical axes corresponding to the x, y and z axes, respectively, of a three-dimensional Cartesian coordinate system. The electrode assembly comprises a population of unit cells, each unit cell comprises an electrode current collector layer, an electrode layer, a separator layer, a counter-electrode layer, and a counter-electrode current collector layer in stacked succession in the longitudinal direction. The electrode layer comprises an electrode active material, and the counter-electrode layer comprises a counter-electrode active material. One of the electrode active material and the counter-electrode material is a cathodically active material and the other of the electrode active material and the counter-electrode material is an anodically active material. A subset of the unit cell population further comprises a pair of spacer members located in the stacked succession between the electrode current collector layer and the counter-electrode current collector layer. One of the spacer members is spaced in the transverse direction from the other spacer member. At least a portion of the counter-electrode active material of the counter-electrode layer is located between the spacer members such that the portion of the counter-electrode active material and the spacer members lie in a common plane defined by the x and z axes.
Another embodiment includes an electrode assembly having mutually perpendicular transverse, longitudinal, and vertical axes corresponding to the x, y and z axes, respectively, of a three-dimensional Cartesian coordinate system. The electrode assembly comprises a population of unit cells, each unit cell comprises an electrode current collector layer, an electrode layer, a separator layer, a counter-electrode layer, and a counter-electrode current collector layer in stacked succession in the longitudinal direction. The electrode layer comprises an electrode active material, and the counter-electrode layer comprises a counter-electrode active material. One of the electrode active material and the counter-electrode material is a cathodically active material and the other of the electrode active material and the counter-electrode material is an anodically active material. A subset of the unit cell population further comprises a pair of spacer members located in the stacked succession between the electrode current collector layer and the counter-electrode current collector layer. One of the spacer members is spaced in the transverse direction from the other spacer member. At least a portion of the counter-electrode active material of the counter-electrode layer is located between the spacer members such that the portion of the counter-electrode active material and the spacer members lie in a common plane defined by the x and z axes.
Another embodiment includes a method of manufacturing a unit cell for use with a secondary battery. The method comprises stacking an electrode current collector layer, an electrode layer, a separator layer, a counter-electrode layer, and a counter-electrode current collector layer in succession in the longitudinal direction. The electrode layer comprises an electrode active material, and the counter-electrode layer comprises a counter-electrode active material. One of the electrode active material and the counter-electrode material is a cathodically active material and the other of the electrode active material and the counter-electrode material is an anodically active material. The method includes placing a pair of spacer members in the stacked succession between the electrode current collector layer and the counter-electrode current collector layer. One of the spacer members is spaced in a transverse direction from the other spacer member. At least a portion of the counter-electrode active material of the counter-electrode layer is located between the spacer members such that the portion of the counter-electrode active material and the spacer members lie in a common plane defined by an x axis and a z axis.
Another embodiment includes a method of manufacturing an electrode assembly for use with a secondary battery. The method comprises stacking an electrode current collector layer, an electrode layer, a separator layer, a counter-electrode layer, and a counter-electrode current collector layer in succession in the longitudinal direction. The electrode layer comprises an electrode active material, and the counter-electrode layer comprises a counter-electrode active material. One of the electrode active material and the counter-electrode material is a cathodically active material and the other of the electrode active material and the counter-electrode material is an anodically active material. The method includes placing a pair of spacer members in the stacked succession between the electrode current collector layer and the counter-electrode current collector layer. One of the spacer members is spaced in a transverse direction from the other spacer member. At least a portion of the counter-electrode active material of the counter-electrode layer is located between the spacer members such that the portion of the counter-electrode active material and the spacer members lie in a common plane defined by an x axis and a z axis.
Another embodiment includes a method for merging a plurality of webs of electrode materials. The process comprises unwinding a first web of the electrode material along a first web merge path, the first web comprising a population of electrode sub-units delineated by corresponding weakened tear patterns and a population of first conveying features. The process further includes unwinding a second web of the electrode material along a second web merge path downstream of the first web merge path, the second web comprising a population of electrode sub-units delineated by corresponding weakened tear patterns and a population of second conveying features. The process also includes conveying a belt comprising a plurality of projections in a web merge direction adjacent the first web merge path and the second web merge path. The plurality of projections is configured to engage with the first conveying features of the first web and the second conveying features of the second web. The process further includes inserting a population of spacer members between the first web of electrode material and the second web of electrode material. The process includes overlaying the second web of the electrode material on the first web of electrode material at a second web merge location downstream of the first web merge location, the population of spacer members being captured between the first web of electrode material and the second web of electrode material.
Yet another embodiment includes a battery for cycling between a charged state and a discharged state, the battery comprising an enclosure and an electrode assembly disposed within the enclosure, wherein the electrode assembly has mutually perpendicular transverse, longitudinal, and vertical axes corresponding to the x, y and z axes, respectively, of a three-dimensional Cartesian coordinate system. The electrode assembly comprises a population of unit cells, each unit cell having a main body, a first edge margin, a second edge margin separated in the transverse direction from the first edge margin, a front, a back separated in the longitudinal direction from the front, a top, and a bottom separated in the vertical direction from the top, each main body comprising an electrode current collector layer, an electrode layer, a separator layer, a counter-electrode layer, and a counter-electrode current collector layer in stacked succession in the longitudinal direction. The electrode layer comprises an electrode active material, and the counter-electrode layer comprises a counter-electrode active material, wherein one of the electrode active material and the counter-electrode material is a cathodically active material and the other of the electrode active material and the counter-electrode material is an anodically active material. Each of the first edge margin and the second edge margin comprises (i) the electrode current collector layer, the separator layer, and the counter-electrode current collector layer, and (ii) a tape spacer, each of the tape spacers being adhered to at least one of (i) the electrode current collector, (ii) the electrode layer, (iii) the separator, and (iv) the counter-electrode current collector, the counter-electrode layer having a first end and a second end spaced in the transverse direction from the first end to define a transverse extent of the counter-electrode layer, the transverse extent of the counter-electrode layer terminating prior to the first edge margin and second edge margin.
Yet another embodiment includes an electrode assembly for cycling between a charged state and a discharged state in a battery, the battery comprising an enclosure and an electrode assembly disposed within the enclosure, wherein the electrode assembly has mutually perpendicular transverse, longitudinal, and vertical axes corresponding to the x, y and z axes, respectively, of a three-dimensional Cartesian coordinate system. The electrode assembly comprises a population of unit cells, each unit cell having a main body, a first edge margin, a second edge margin separated in the transverse direction from the first edge margin, a front, a back separated in the longitudinal direction from the front, a top, and a bottom separated in the vertical direction from the top, each main body comprising an electrode current collector layer, an electrode layer, a separator layer, a counter-electrode layer, and a counter-electrode current collector layer in stacked succession in the longitudinal direction. The electrode layer comprises an electrode active material, and the counter-electrode layer comprises a counter-electrode active material, wherein one of the electrode active material and the counter-electrode material is a cathodically active material and the other of the electrode active material and the counter-electrode material is an anodically active material. Each of the first edge margin and the second edge margin comprises (i) the electrode current collector layer, the separator layer, and the counter-electrode current collector layer, and (ii) a tape spacer, each of the tape spacers being adhered to at least one of (i) the electrode current collector, (ii) the electrode layer, (iii) the separator, and (iv) the counter-electrode current collector, the counter-electrode layer having a first end and a second end spaced in the transverse direction from the first end to define a transverse extent of the counter-electrode layer, the transverse extent of the counter-electrode layer terminating prior to the first edge margin and second edge margin.
Still another embodiment includes a unit cell for a battery configured to cycle between a charged state and a discharged state, the unit cell having mutually perpendicular transverse, longitudinal, and vertical axes corresponding to the x, y and z axes, respectively, of a three-dimensional Cartesian coordinate system, the unit cell having a main body, a first edge margin, a second edge margin separated in the transverse direction from the first edge margin, a front, a back separated in the longitudinal direction from the front, a top, and a bottom in the vertical direction from the top, the main body comprising an electrode current collector layer, an electrode layer, a separator layer, a counter-electrode layer, counter-electrode layer, and a counter-electrode current collector layer in stacked succession in the longitudinal direction. The electrode layer comprises an electrode active material, and the counter-electrode layer comprises a counter-electrode active material, wherein one of the electrode active material and the counter-electrode material is a cathodically active material and the other of the electrode active material and the counter-electrode material is an anodically active material. Each of the first edge margin and the second edge margins of the main body comprises (i) the electrode current collector layer, the separator layer, and the counter-electrode current collector layer, and (ii) a first tape spacer disposed in the first edge margin and a second tape spacer disposed in the second edge margin; each of the first tape spacer and the second tape spacer being adhered to at least one of (i) the electrode current collector, (ii) the electrode layer, (iii) the separator, and (iv) the counter-electrode current collector, the counter-electrode layer having a first end and a second end spaced in the transverse direction from the first end to define a transverse extent of the counter-electrode layer, the transverse extent of the counter-electrode layer terminating prior to the first edge margin and second edge margin.
Still another embodiment includes an electrode assembly for a battery configured to cycle between a charged state and a discharged state, the electrode assembly having mutually perpendicular transverse, longitudinal, and vertical axes corresponding to the x, y and z axes, respectively, of a three-dimensional Cartesian coordinate system, the electrode assembly having a main body, a first edge margin, a second edge margin separated in the transverse direction from the first edge margin, a front, a back separated in the longitudinal direction from the front, a top, and a bottom in the vertical direction from the top, the main body comprising an electrode current collector layer, an electrode layer, a separator layer, a counter-electrode layer, counter-electrode layer, and a counter-electrode current collector layer in stacked succession in the longitudinal direction. The electrode layer comprises an electrode active material, and the counter-electrode layer comprises a counter-electrode active material, wherein one of the electrode active material and the counter-electrode material is a cathodically active material and the other of the electrode active material and the counter-electrode material is an anodically active material. Each of the first edge margin and the second edge margins of the main body comprises (i) the electrode current collector layer, the separator layer, and the counter-electrode current collector layer, and (ii) a first tape spacer disposed in the first edge margin and a second tape spacer disposed in the second edge margin; each of the first tape spacer and the second tape spacer being adhered to at least one of (i) the electrode current collector, (ii) the electrode layer, (iii) the separator, and (iv) the counter-electrode current collector, the counter-electrode layer having a first end and a second end spaced in the transverse direction from the first end to define a transverse extent of the counter-electrode layer, the transverse extent of the counter-electrode layer terminating prior to the first edge margin and second edge margin.
Another embodiment includes a method of preparing a unit cell for a battery configured to cycle between a charged state and a discharged state, the method comprising: stacking an electrode current collector layer, an electrode layer, a separator layer, a counter-electrode layer, and a counter-electrode current collector layer in stacked succession in the longitudinal direction; wherein the electrode layer comprises an electrode active material, and the counter-electrode layer comprises a counter-electrode active material, wherein one of the electrode active material and the counter-electrode material is a cathodically active material and the other of the electrode active material and the counter-electrode material is an anodically active material, adhering a tape spacer to at least one of the electrode current collector layer, the electrode layer, the separator layer, the counter-electrode layer, or the counter-electrode current collector layer within a first edge margin and a second edge margin such that the first edge margin and the second edge margin comprises (i) the electrode current collector layer, the separator layer, and the counter-electrode current collector layer, and (ii) the tape spacer, wherein the counter-electrode layer has a first end and a second end spaced in the transverse direction from the first end to define a transverse extent of the counter-electrode layer, and the counter-electrode layer is provided such that the transverse extent of the counter electrode layer terminates prior to the first edge margin and second edge margin.
Another embodiment includes a method of preparing an electrode assembly for a battery configured to cycle between a charged state and a discharged state, the method comprising: stacking an electrode current collector layer, an electrode layer, a separator layer, a counter-electrode layer, and a counter-electrode current collector layer in stacked succession in the longitudinal direction; wherein the electrode layer comprises an electrode active material, and the counter-electrode layer comprises a counter-electrode active material, wherein one of the electrode active material and the counter-electrode material is a cathodically active material and the other of the electrode active material and the counter-electrode material is an anodically active material, adhering a tape spacer to at least one of the electrode current collector layer, the electrode layer, the separator layer, the counter-electrode layer, or the counter-electrode current collector layer within a first edge margin and a second edge margin such that the first edge margin and the second edge margin comprises (i) the electrode current collector layer, the separator layer, and the counter-electrode current collector layer, and (ii) the tape spacer, wherein the counter-electrode layer has a first end and a second end spaced in the transverse direction from the first end to define a transverse extent of the counter-electrode layer, and the counter-electrode layer is provided such that the transverse extent of the counter electrode layer terminates prior to the first edge margin and second edge margin.
FIGS. 14C1-C3 illustrate a side, front and top view, respectively of the merging arrangement according to the present disclosure.
FIGS. 14E1-E2 include side views and FIGS. 14E3-E4 include top views of untapered (top) and tapered (bottom) projections according to embodiments of the disclosure.
FIG. 14F1 shows an isometric view (left), FIG. 14F2 shows a top view and FIG. 14F3 shows side view (right) of counter rotating brushes according to an embodiment of the present disclosure.
FIGS. 14H1-H3 show three views, a top view, a side view and a perspective view, respectively, of a web interacting with a merge sprocket according to an embodiment of the present disclosure.
“A,” “an,” and “the” (i.e., singular forms) as used herein refer to plural referents unless the context clearly dictates otherwise. For example, in one instance, reference to “an electrode” includes both a single electrode and a plurality of similar electrodes.
“About” and “approximately” as used herein refers to plus or minus 10%, 5%, or 1% of the value stated. For example, in one instance, about 250 μm would include 225 μm to 275 μm. By way of further example, in one instance, about 1,000 μm would include 900 μm to 1,100 μm. Unless otherwise indicated, all numbers expressing quantities (e.g., measurements, and the like) and so forth used in the specification and claims are to be understood as being modified in all instances by the term “about.” Accordingly, unless indicated to the contrary, the numerical parameters set forth in the following specification and attached claims are approximations. Each numerical parameter should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques.
“Anode” as used herein in the context of a secondary battery refers to the negative electrode in the secondary battery.
“Anode material” or “Anodically active” as used herein means material suitable for use as the negative electrode of a secondary battery
“Cathode” as used herein in the context of a secondary battery refers to the positive electrode in the secondary battery
“Cathode material” or “Cathodically active” as used herein means material suitable for use as the positive electrode of a secondary battery.
“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.
“Counter electrode” as used herein may refer to the negative or positive electrode (anode or cathode), opposite of the Electrode, of a secondary battery unless the context clearly indicates otherwise.
“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.
“Electrochemically active material” as used herein means anodically active or cathodically active material.
“Electrode” as used herein may refer to the negative or positive electrode (anode or cathode) of a secondary battery unless the context clearly indicates otherwise.
“Electrode current collector layer” as used herein may refer to an anode (e.g., negative) current collector layer or a cathode (e.g., positive) current collector layer.
“Electrode material” as used herein may refer to anode material or cathode material unless the context clearly indicates otherwise.
“Electrode structure” as used herein may refer to an anode structure (e.g., negative electrode structure) or a cathode structure (e.g., positive electrode structure) adapted for use in a battery unless the context clearly indicates otherwise.
“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 coordinate system 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. “Weakened region” refers to a portion of the web that has undergone a processing operation such as scoring, cutting, perforation or the like such that the local rupture strength of the weakened region is lower than the rupture strength of a non-weakened region.
Embodiments of the present disclosure relate to apparatuses, systems and methods for the production of electrode components for batteries, such as three-dimensional secondary batteries that improve the speed of manufacture of the battery components, while retaining or improving battery capacity and battery longevity, and reducing the occurrences of defects during the manufacturing process.
An exemplary system for the production of electrode components, including electrodes and separators, for use in batteries will be described with reference to
In the illustrated exemplary embodiment, the production system 100 includes a base unwind roller 102 for holding and unwinding a web of base material 104. The web of base material 104 may be a web of electrode material (i.e., a web of anode material or a web of cathode material), separator material or the like suitable for the production of an electrode assembly for a secondary battery. The web of base material 104 is a thin sheet of material that has been wound into the form of a roll, having a center through hole sized for placement on the base unwind roller 102. In some embodiments, the web of base material 104 is a multi-layer material including, for example, an electrode current collector layer (i.e., an anode current collector layer or a cathode current collector layer), and an electrochemically active material layer (i.e., a layer of anodically active material or a layer of cathodically active material) on at least one major surface thereof, and in other embodiments the web of base material may be a single layer (e.g., a web of separator material). The base unwind roller 102 may be formed from metal, metal alloy, composite, plastic or any other material that allows the production system 100 to function as described herein. In one embodiment, the unwind roller 102 is made of stainless steel and has a diameter of 3 inches (76.2 mm).
As seen in the embodiment of
The splicing station 110 is configured to facilitate splicing two separate webs together. In one suitable embodiment, as a first web of base material 104 is unwound, such that a trailing edge (not shown) of the web of base material 104 is stopped within the splicing station 110, a leading edge (not shown) of a second web of base material 104 is unwound into the splicing station 110 such that the trailing edge of the first web and the leading edge of the second web are adjacent one another. The user may then apply an adhesive, such as an adhesive tape, to join the leading edge of the second web to the trailing edge of the first web to form a seam between the two webs and create a continuous web of base material. Such process may be repeated for numerous webs of base material 104, as dictated by a user. Thus, the splicing station 110 allows for the possibility of having multiple webs of base material being spliced together to form one continuous web. It should be appreciated that in other embodiments, a user may splice webs of the same, or different, materials together if desired.
In one suitable embodiment, upon exiting the splicing station 110, the web of base material 104 is then conveyed in the down-web direction WD such that it may enter a nip roller 112. The nip roller 112 is configured to facilitate controlling the speed at which the web of base material 104 is conveyed through the production system 100. In one embodiment, the nip roller 112 includes at least two adjacent rollers having a space therebetween defining a nip. The nip is sized such that the web of base material 104 is pressed against each of the two adjacent rollers 114, with enough pressure to allow friction of the rollers to move the web of base material 104, but a low enough pressure to avoid any significant deformation or damage to the web of base material 104. In some suitable embodiments, the pressure exerted against the web of base material 104 by adjacent rollers 114 (e.g., nip rollers) is set between 0 to 210 pounds of force across the cross-web span of the web SW (i.e., the edge to edge distance of the web in the cross-web direction XWD) (
In one suitable embodiment, at least one of the adjacent rollers 114 is a compliant roller which may be a high friction roller driven by an electric motor, and another of the adjacent rollers is a low friction passive roller. The compliant roller may have at least an exterior surface made from rubber or polymer capable of providing sufficient grip on the web of base material 104 to provide a pushing or pulling force on the web of base material 104 to convey it through the production system 100. In one embodiment, at least one of the adjacent rollers 114 is a steel roller having a diameter of about 3.863 inches (98.12 mm). In another embodiment, at least one of the adjacent rollers 114 is a rubber roller having a diameter of about 2.54 inches (64.51 mm). In yet another embodiment, one or more of the adjacent rollers 114 include a rubber ring placed thereon which may be adjusted for placement at any location along the width of the roller, each ring having an outer diameter of about 3.90 inches (99.06 mm). In one embodiment, one or more rubber rings are placed on the rollers to contact the web of base material 104 at a continuous outer edge thereof to drive the web of base material 104 in the down-web direction WD. Accordingly, the speed of the web of base material 104 is controlled by controlling the rate of rotation of the high friction roller via a user interface 116. In embodiments, the speed of the web in the web direction is controlled to be from 0.001 m/s to 10 m/s. In embodiments, the maximum speed of the web in the web direction WD is dictated by the inertia of the web and system components, such that the web maintains proper alignment, flatness and tensioning as further described herein. In other embodiments, each of the adjacent rollers 114 may be made from any high friction or low friction material, that allows the production system 100 to function as described herein. It should be appreciated that either or both of the adjacent rollers 114 may be connected to a motor (not shown) for controlling the speed of the web of base material 104 passing through the nip. The production system 100 may include one or more additional nip rollers 122, 132 to facilitate control of the speed of the web of base material 104 conveyed through the production system 100, which may be controlled via the user interface 116. When multiple nip rollers are used, each of the nip rollers may be set via the user interface 116 to the same speed such that the web of base material 104 is conveyed smoothly through production system 100. In embodiments, the speed of the web of base material 104 in the web direction WD is controlled to be from 0.001 m/s to 10 m/s.
The production system 100 may also include a dancer 118. As seen in
The production system 100 includes one or more laser systems 120a, 120b, 120c. The embodiment shown in
The exemplary production system 100 illustrated in
The production system 100 of
In one suitable embodiment, the web of base material 104 is rewound via a rewind roller 134 together with a web of interleaf material 138, which is unwound via interleaf roller 136 to create a roll of electrodes 140 with layers of the electrodes separated by interleaf material 138. In some embodiments, the web of base material 104 can be rewound via the rewind roller 134 without the web of interleaf material 138.
It should be noted that the series of nip rollers 112, 122, 132, idlers 108a-x, and dancers 118a-x may be together referred to as a conveying system for conveying the web of base material 104 through the production system 100. As used herein, conveying system or conveying of the web of base material 104 refers to intended movement of the web of base material 104 through the production system in the web direction WD.
With reference to
In another suitable embodiment and with reference still to
In general, when the web of base material 104 is a web of anode material, the anodically active material layer(s) thereof will (each) have a thickness of at least about 10 um. For example, in one embodiment, the anodically active material layer(s) will (each) have a thickness of at least about 40 um. By way of further example, in one such embodiment, the anodically active material layer(s) will (each) have a thickness of at least about 80 um. By way of further example, in one such embodiment, the anodically active material layers will (each) have a thickness of at least about 120 um. Typically, however, the anodically active material layer(s) will (each) have a thickness of less than about 60 um or even less than about 30 um.
In general, the negative electrode active material may be selected from the group consisting of: (a) silicon (Si), germanium (Ge), tin (Sn), lead (Pb), antimony (Sb), bismuth (Bi), zinc (Zn), aluminum (Al), titanium (Ti), nickel (Ni), cobalt (Co), and cadmium (Cd); (b) alloys or intermetallic compounds of Si, Ge, Sn, Pb, Sb, Bi, Zn, Al, Ti, Ni, Co, or Cd with other elements; (c) oxides, carbides, nitrides, sulfides, phosphides, selenides, and tellurides of Si, Ge, Sn, Pb, Sb, Bi, Zn, Al, Ti, Fe, Ni, Co, V, or Cd, and their mixtures, composites, or lithium-containing composites; (d) salts and hydroxides of Sn; (e) lithium titanate, lithium manganate, lithium aluminate, lithium-containing titanium oxide, lithium transition metal oxide, ZnCo2O4; (f) particles of graphite and carbon; (g) lithium metal, and (h) combinations thereof.
Exemplary anodically active materials include carbon materials such as graphite and soft or hard carbons, or graphene (e.g., single-walled or multi-walled carbon nanotubes), or any of a range of metals, semi-metals, alloys, oxides, nitrides and compounds capable of intercalating lithium or forming an alloy with lithium. Specific examples of the metals or semi-metals capable of constituting 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, and mixtures thereof. In one exemplary embodiment, the anodically active material comprises aluminum, tin, or silicon, or an oxide thereof, a nitride thereof, a fluoride thereof, or other alloy thereof. In another exemplary embodiment, the anodically active material comprises silicon or an alloy or oxide thereof.
In one embodiment, the anodically active material is 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 negative electrode active material during charging and discharging processes. In general, the void volume fraction of (each of) the anodically active material layer(s) is at least 0.1. Typically, however, the void volume fraction of (each of) the anodically active material layer(s) is not greater than 0.8. For example, in one embodiment, the void volume fraction of (each of) the anodically active material layer(s) is about 0.15 to about 0.75. By way of the further example, in one embodiment, the void volume fraction of (each of) the anodically active material layer(s) is about 0.2 to about 0.7. By way of the further example, in one embodiment, the void volume fraction of (each of) the anodically active material layer(s) is about 0.25 to about 0.6.
Depending upon the composition of the microstructured anodically active material and the method of its formation, the microstructured anodically active material 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 nm, a wall dimension of less than 10 nm, a pore depth of 1-50 micrometers, 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 10-50 nm, a wall dimension of 10-50 nm, a pore depth of 1-100 micrometers, 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 1-500 micrometers, 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 one embodiment, the void volume comprises open voids, that is, the negative electrode active material contains voids having openings at the lateral surface of the negative electrode active material through which lithium ions (or other carrier ions) can enter or leave the anodically active material; for example, lithium ions may enter the anodically active material through the void openings after leaving the cathodically active material. In another embodiment, the void volume comprises closed voids, that is, the anodically active material contains voids that are enclosed by anodically active material. In general, open voids can provide greater interfacial surface area for the carrier ions whereas closed voids tend to be less susceptible to solid electrolyte interface while each provides room for expansion of the anodically active material upon the entry of carrier ions. In certain embodiments, therefore, it is preferred that the anodically active material comprise a combination of open and closed voids.
In one embodiment, the anodically active material comprises 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 will generally have a porosity fraction of at least about 0.1, but less than 0.8 and have a thickness of about 1 to about 100 micrometers. For example, in one embodiment, the anodically active material comprises porous silicon, has a thickness of about 5 to about 100 micrometers, and has a porosity fraction of about 0.15 to about 0.75. By way of further example, in one embodiment, the anodically active material comprises porous silicon, has a thickness of about 10 to about 80 micrometers, and has a porosity fraction of about 0.15 to about 0.7. By way of further example, in one such embodiment, the anodically active material comprises porous silicon, has a thickness of about 20 to about 50 micrometers, and has a porosity fraction of about 0.25 to about 0.6. By way of further example, in one embodiment, the anodically active material comprises a porous silicon alloy (such as nickel silicide), has a thickness of about 5 to about 100 micrometers, and has a porosity fraction of about 0.15 to about 0.75.
In another embodiment, the anodically active material layer comprises 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. 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 will generally have a porosity fraction of at least about 0.1, but less than 0.8 and have a thickness of about 1 to about 200 micrometers. For example, in one embodiment, the anodically active material comprises silicon nanowires, has a thickness of about 5 to about 100 micrometers, and has a porosity fraction of about 0.15 to about 0.75. By way of further example, in one embodiment, the anodically active material comprises silicon nanowires, has a thickness of about 10 to about 80 micrometers, and has a porosity fraction of about 0.15 to about 0.7. By way of further example, in one such embodiment, the anodically active material comprises silicon nanowires, has a thickness of about 20 to about 50 micrometers, and has a porosity fraction of about 0.25 to about 0.6. By way of further example, in one embodiment, the anodically active material comprises nanowires of a silicon alloy (such as nickel silicide), has a thickness of about 5 to about 100 micrometers, and has a porosity fraction of about 0.15 to about 0.75.
In yet other embodiments, the negative electrode (i.e., the electrode or the counter-electrode) is coated with a particulate lithium material selected from the group consisting of stabilized lithium metal particles, e.g., lithium carbonate-stabilized lithium metal powder, lithium silicate stabilized lithium metal powder, or other source of stabilized lithium metal powder or ink. The particulate lithium material may be applied on the negative electrode active material layer by spraying, loading or otherwise disposing the lithium particulate material onto the negative electrode active material layer at a loading amount of about 0.05 to 5 mg/cm2, e.g., about 0.1 to 4 mg/cm2, or even about 0.5 to 3 mg/cm2. The average particle size (D50) of the lithium particulate material may be 5 to 200 μm, e.g., about 10 to 100 μm, 20 to 80 μm, or even about 30 to 50 μm. The average particle size (D50) may be defined as a particle size corresponding to 50% in a cumulative volume-based particle size distribution curve. The average particle size (D50) may be measured, for example, using a laser diffraction method.
In general, the anode current collector will have an electrical conductivity of at least about 103 Siemens/cm. For example, in one such embodiment, the anode current collector will have a conductivity of at least about 104 Siemens/cm. By way of further example, in one such embodiment, the anode current collector will have a conductivity of at least about 105 Siemens/cm. Exemplary electrically conductive materials suitable for use as anode current collectors include metals, such as, copper, nickel, cobalt, titanium, and tungsten, and alloys thereof.
Referring again to
In general, when the web of base material 104 is a web of cathode material, the cathodically active material layer(s) thereof will (each) have a thickness of at least about 20 μm. For example, in one embodiment, the cathodically active material layer(s) will (each) have a thickness of at least about 40 μm. By way of further example, in one such embodiment the cathodically active material layer(s) will (each) have a thickness of at least about 60 μm. By way of further example, in one such embodiment the cathodically active material layers will (each) have a thickness of at least about 100 μm. Typically, however, the cathodically active material layer(s) will (each) have a thickness of less than about 90 μm or even less than about 70 μm.
In one embodiment, the positive electrode may comprise, or may be, an intercalation-type chemistry active material, a conversion chemistry active material, or a combination thereof.
Exemplary conversion chemistry materials useful in the present disclosure include, but are not limited to, S (or Li2S in the lithiated state), LiF, Fe, Cu, Ni, FeF2, FeOdF3.2d, FeF3, CoF3, CoF2, CuF2, NiF2, where 0≤d≤0.5, and the like.
Exemplary cathodically active materials also include any of a wide range of intercalation type cathodically active materials. For example, for a lithium-ion battery, the cathodically active material 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 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, 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, and Au. Additional cathode active materials include LiCoO2, LiNi0.5 Mn1.5O4, Li(NixCoyAlz)O2, LiFePO4, Li2MnO4, V2O5, molybdenum oxysulfides, phosphates, silicates, vanadates, sulfur, sulfur compounds, oxygen (air), Li(NixMnyCoz)O2, and combinations thereof.
In general, the cathode current collector will have an electrical conductivity of at least about 103 Siemens/cm. For example, in one such embodiment, the cathode current collector will have a conductivity of at least about 104 Siemens/cm. By way of further example, in one such embodiment, the cathode current collector will have a conductivity of at least about 105 Siemens/cm. Exemplary cathode current collectors include metals, such as aluminum, nickel, cobalt, titanium, and tungsten, and alloys thereof.
Referring again to
In general, when the web of base material 104 is a web of electrically insulating separator material, the electrically insulating separator material will have a thickness of at least about 4 μm. For example, in one embodiment, the electrically insulating separator material will have a thickness of at least about 8 um. By way of further example, in one such embodiment the electrically insulating separator material will have a thickness of at least about 12 μm. By way of further example, in one such embodiment the electrically insulating separator material will have a thickness of at least about 15 μm. Typically, however, the electrically insulating separator material will have a thickness of less than about 12 μm or even less than about 10 μm.
In general, the separator may be selected from a wide range of separators having the capacity to conduct carrier ions between the positive and negative active material of a unit cell. For example, the separator may comprise a microporous separator material that may be permeated with a liquid, nonaqueous electrolyte. Alternatively, the separator may comprise a gel or solid electrolyte capable of conducting carrier ions between the positive and negative electrodes of a unit cell.
In one embodiment, the separator may comprise a polymer based electrolyte. Exemplary polymer electrolytes include PEO-based polymer electrolytes, polymer-ceramic composite electrolytes, polymer-ceramic composite electrolytes, and polymer-ceramic composite electrolyte.
In another embodiment, the separator may comprise an oxide based electrolyte. Exemplary oxide-based electrolytes include lithium lanthanum titanate (Li0.34La0.56TiO3), Al-doped lithium lanthanum zirconate (Li6.24La3Zr2Al0.24O11.98), Ta-doped lithium lanthanum zirconate (Li6.4La3Zr1.4Ta0.6O12) and lithium aluminum titanium phosphate (Li1.4Al0.4Ti1.6(PO4)3).
In another embodiment, the separator may comprise a solid electrolyte. Exemplary solid electrolytes include sulfide based electrolytes such as lithium tin phosphorus sulfide (Li10SnP2S12), lithium phosphorus sulfide (β-Li3PS4) and lithium phosphorus sulfur chloride iodide (Li6PS5Cl0.9I0.1).
In one embodiment, the separator comprises a microporous separator material comprising a particulate material and a binder, and having a porosity (void fraction) of at least about 20 vol. %. The pores of the microporous separator material will have a diameter of at least 50 Å and will typically fall within the range of about 250 to 2,500 Å. The microporous separator material will typically have a porosity of less than about 75%. In one embodiment, the microporous separator material has a porosity (void fraction) of at least about 25 vol %. In one embodiment, the microporous separator material will have a porosity of about 35-55%.
The binder for the microporous separator material may be selected from a wide range of inorganic or polymeric materials. For example, in one embodiment, the binder is an organic material selected from the group consisting of silicates, phosphates, aluminates, aluminosilicates, and hydroxides such as magnesium hydroxide, calcium hydroxide, etc. For example, in one embodiment, the binder is a fluoropolymer derived from monomers containing vinylidene fluoride, hexafluoropropylene, tetrafluoropropene, and the like. In another embodiment, the binder is a polyolefin such as polyethylene, polypropylene, or polybutene, having any of a range of varying molecular weights and densities. In another embodiment, the binder is selected from the group consisting of ethylene-diene-propene terpolymer, polystyrene, polymethyl methacrylate, polyethylene glycol, polyvinyl acetate, polyvinyl butyral, polyacetal, and polyethyleneglycol diacrylate. In another embodiment, the binder is 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 another embodiment, the binder is selected from the group consisting of acrylates, styrenes, epoxies, and silicones. In another embodiment, the binder is a copolymer or blend of two or more of the aforementioned polymers.
The particulate material comprised by the microporous separator material may also be selected from a wide range of materials. In general, 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. For example, in one embodiment, the particulate material has a conductivity for carrier ions (e.g., lithium) of less than 1×10−4 S/cm. By way of further example, in one embodiment, the particulate material has a conductivity for carrier ions of less than 1×10−5 S/cm. By way of further example, in one embodiment, the particulate material has a conductivity for carrier ions of less than 1×10−6 S/cm. Exemplary particulate materials include particulate polyethylene, polypropylene, a TiO2-polymer composite, silica aerogel, fumed silica, silica gel, silica hydrogel, silica xerogel, silica sol, colloidal silica, alumina, titanic, magnesia, kaolin, talc, diatomaceous earth, calcium silicate, aluminum silicate, calcium carbonate, magnesium carbonate, or a combination thereof. For example, in one embodiment, the particulate material comprises a particulate oxide or nitride such as TiO2, SiO2, Al2O3, GeO2, B2O3, Bi2O3, BaO, ZnO, ZrO2, BN, Si3N4, Ge3N4. See, for example, P. Arora and J. Zhang, “Battery Separators” Chemical Reviews 2004, 104, 4419-4462). In one embodiment, the particulate material will have an average particle size of about 20 nm to 2 micrometers, more typically 200 nm to 1.5 micrometers. In one embodiment, the particulate material will have an average particle size of about 500 nm to 1 micrometer.
In an alternative embodiment, the particulate material comprised by the microporous separator material may be bound by techniques such as sintering, binding, curing, etc. while maintaining the void fraction desired for electrolyte ingress to provide the ionic conductivity for the functioning of the battery.
In an assembled energy storage device, the microporous separator material is permeated with a non-aqueous electrolyte suitable for use as a secondary battery electrolyte. Typically, the non-aqueous electrolyte comprises a lithium salt and/or mixture of salts dissolved in an organic solvent and/or solvent mixture. Exemplary lithium salts include inorganic lithium salts such as LiClO4, LiBF4, LiPF6, LiAsF6, LiCl, and LiBr; and organic lithium salts such as LiB(C6H5)4, LiN(SO2CF3)2, LiN(SO2CF3)3, LiNSO2CF3, LiNSO2CF5, LiNSO2C4F9, LiNSO2C5F11, LiNSO2C6F13, and LiNSO2C7F15. Exemplary organic solvents to dissolve the lithium salt include cyclic esters, chain esters, cyclic ethers, and chain ethers. Specific examples of the cyclic esters include propylene carbonate, butylene carbonate, γ-butyrolactone, vinylene carbonate, 2-methyl-γ-butyrolactone, acetyl-γ-butyrolactone, and γ-valerolactone. Specific examples of the chain esters 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 alkyl acetates. Specific examples of the cyclic ethers include tetrahydrofuran, alkyltetrahydrofurans, dialkyltetrahydrofurans, alkoxytetrahydrofurans, dialkoxytetrahydrofurans, 1,3-dioxolane, alkyl-1,3-dioxolanes, and 1,4-dioxolane. Specific examples of the chain ethers include 1,2-dimethoxyethane, 1,2-diethoxythane, diethyl ether, ethylene glycol dialkyl ethers, diethylene glycol dialkyl ethers, triethylene glycol dialkyl ethers, and tetraethylene glycol dialkyl ethers.
In one embodiment, the microporous separator may be permeated with a non-aqueous, organic electrolyte including a mixture of a lithium salt and a high-purity organic solvent. In addition, the electrolyte may be a polymer using a polymer electrolyte or a solid electrolyte.
In one embodiment, web of base material 104 may have an adhesive tape layer (not shown) adhered to one or both surfaces of the anodically active material layer 508, or cathodically active material layer 512, respectively. The adhesive layer may then later be removed subsequent to ablation and cutting (described below) to remove unwanted material or debris.
Embodiments of the laser systems 120a-c are further described with reference to
As seen in
In one suitable embodiment, the chuck 306 is formed from aluminum. However, the chuck 306 may be formed from aluminum alloy, composites, metals or metal alloys or any other suitable material that allows chuck 306 to function as described herein.
In one suitable embodiment, the web of base material 104 is first ablated by laser beam 302 (
With further reference to
The laser system 120a is configured to cut one or more patterns (such as individual electrode patterns 800 (
It should be appreciated that, although the laser processing operations as described herein such that the lengthwise edge cuts 600 are defined in the cross-web direction XWD, such that repeating patterns of electrode patterns are aligned in the cross-web direction XWD, in other embodiments, the laser processing operations described herein can be controlled such that the lengthwise edge cuts 600, and all associated cuts, perforations and ablation operations are oriented respectively perpendicular. For example, lengthwise edge cuts 600 can be aligned in the down-web direction WD, such that populations of electrode patterns 800 are aligned in the down-web direction WD, rather than the cross-web direction XWD.
In one embodiment, laser system 120a cuts a tie bar 614 between one or more of the electrode patterns. The tie bar 614 may be used to delineate between groups of the electrode patterns. For example, in the embodiment shown in
In addition, in one suitable embodiment, the laser system 120a cuts one or more of the repeating alignment features such as a plurality of the fiducial features 602 in the web of base material 104. In one embodiment, the fiducial features 602 are fiducial through-holes. The fiducial features 602 are cut at a known location on the web of base material 104. The fiducial features 602 are shown as circular in
With reference to
Similarly, with further reference to
With reference to
In one suitable embodiment, the laser system 120a is configured as a first ablation station. In this embodiment, the laser system 120a forms the ablations 404, as described above on a first surface of the web of base material 104. Upon exiting laser system 120a, the web of base material passes over idler 108d which flips the web of base material 104 in a manner such that a second surface (opposing the first surface) of the web of base material is positioned for processing by the laser system 120b, which is configured as a second ablation station in this embodiment. In this embodiment, the laser system 120b is configured to use the fiducial features 602 to ensure alignment in the down-web direction WD and cross-web direction XWD. Accordingly, the laser system 120b performs a second ablation process on the opposing surface of the web of base material 104, such that ablations 404 on each surface of the web of base material 104 are aligned in the down-web direction WD and the cross-web direction XWD. In one embodiment, the ablations 404 are configured as current collector tabs of the electrodes.
In one embodiment, the laser system 120c seen in
In one suitable embodiment, one or more of the laser devices 300 of the laser systems 120a-c is 20 watt fiber laser. In embodiments, suitable laser devices 300 of the laser systems 120a-c have a laser power within the range of from 10 watts to 5,000 watts, such as from 10 W to 100 W, 100 W to 250 W, 250 W to 1 kW, 1 kW to 2.5 kW, 2.5 kW to 5 kW. Suitable laser devices 300 will include a laser beam having a wavelength of from 150 nm to 10.6 μm, for example such as from 150 nm to 375 nm, 375 nm to 750 nm, 750 nm to 1,500 nm, and 1,500 nm to 10.6 μm. In embodiments, the laser devices 300 will be capable of laser pulse width types of one or more of continuous wave (cw), microsecond (μs), nanosecond (ns), picosecond (ps) and femtosecond (fs) pulse types. Any of these types of lasers may be used alone or in combination as laser devices 300 of laser systems 120a-c. In other suitable embodiments, the laser device 300 is any other laser capable of allowing laser systems 120a-c to perform as described herein.
In some embodiments, the web of base material 104 may include fiducial features 602 that have been machine punched, or laser cut, prior to being loaded into production system 100. In another suitable embodiment, the fiducial features 602 may be mechanically machine punched subsequently to forming ablations 404 on a first surface of the web of base material. In other suitable embodiments, the production system 100 may include one or more additional mechanical punches which may be used to form one or more of the lengthwise edge cuts 600, and/or the first and second perforation 608, 610.
In one embodiment, one or more of the rollers of the conveyor system may not be perfectly round, such that the roller has an eccentricity. In such case, especially if the eccentric roller is a nip roller, the web of base material may be conveyed in a manner such that a position of the web of base material 104 advances in a manner differently depending upon which portion of the eccentric roller is in contact with the web. For example, if the eccentric has a portion of the radius that exceeds the expected radius of the roller, the web may advance further in the down-web direction WD than expected, when the larger radius portion of the roller is pushing/pulling the web. Likewise, if the eccentric roller has a reduced radius portion, the web may advance a reduced distance in the down-web direction WD than expected. Accordingly, in one embodiment, the eccentric roller(s) may be mapped to determine the radius versus radial position. The laser system 120a-c may then be controlled to adjust the laser beam 302 position to account for the eccentricity based upon the mapping of the roller(s). In one embodiment, the mapping of the rollers may be stored in the memory of the user interface 116.
Upon having exited one or more of laser systems 120a-c, the web of base material may be conveyed to one or more cleaning stations such as brushing station 124 and air knife 126. In one suitable embodiment, the brushing station 124 includes a brush 1000 (
In one embodiment, the length of the bristles 1002 is ¾ inch (19.05 mm). In one embodiment, the bristles 1002 are inserted or clamped within bristle holder 1004 by approximately ⅛ inch. The diameter of the bristles may be from 0.003 inch (0.076 mm) to 0.010 inch (0.254 mm), such as 0.003 inch (0.076), 0.004 inch (0.101 mm), inch (0.127 mm), 0.006 inch (0.152 mm), 0.007 inch (0.177 mm), 0.008 inch (0.203 mm), 0.009 inch (0.228 mm) and 0.010 inch (0.254 mm). In one suitable embodiment, the bristles 1002 are nylon bristles. However, in other embodiments the bristles 1002 may be any other natural or synthetic material that allows the brush 1000 to function as described herein.
With further reference to
In one suitable embodiment, a second brush (not shown) is located in a position to contact the opposing surface of the web of base material 104. In this embodiment, the second brush, which may be substantially the same as the first brush 1000 is configured to travel in a direction opposite to the first brush, and suitably 180 degrees out of phase with the first brush. The phase of the first brush and the second brush may be determined via the position sensor 1016, and an equivalent position sensor of the second brush. In this embodiment, the contact pressure of the bristles of the first brush and the second brush, together, must be low enough that it does not break, rupture or otherwise cause defects in the electrode patterns, and maintains the electrode patterns as attached to the web of base material 104.
In one embodiment, the brush 1000 has a bristle width 1022 that is wider in the cross-web direction XWD than the width of web of base material 104 in the cross-web direction XWD. For example, in one embodiment, the bristle width 1022 is of sufficient width that as the brush 1000 oscillates in the cross-web direction XWD, the bristles 1002 remain in contact with the surface of the web of base material 104 throughout the entire range of motion of the brush 1000. The rate of oscillation of the brush 1000 and the pressure exerted by the bristles 1002 against the surface of the web of base material 104 may be controlled by the user using the user interface 116.
The brushing station 124 may be equipped with a vacuum system configured to create a vacuum through brush station orifices 1020 to evacuate debris that has been brushed from one or more surfaces of the web of base material 104. In this embodiment, the debris may be brushed from the web of base material 104 and fall, or be suctioned through the brush station orifices 1020. The brush station orifices 1020 are illustrated as being round, but may be any shape that allows brushing station 124 to function as described herein. Further, the upper edges of the brush station orifices 1020 may be chamfered, and/or staggered in position to allow the web of base material 104 to more easily pass over them without having an edge of the web of base material get snagged thereon. In one embodiment, the vacuum level may be controlled to be from 0 to 140 inches H2O, such as 0 in H2O, 10 in H2O, 20 in H2O, 30 in H2O, 40 in H2O, 50 in H2O, 60 in H2O, 70 in H2O, 80 in H2O, 90 in H2O, 100 in H2O, 110 in H2O, 120 in H2O, 130 in H2O, and 140 in H2O. In some embodiments, the flow rate of the vacuum is controlled to be from about 0 to 425 cubic feet per minute (“cfm”), such as 0 cfm, 25 cfm, 50 cfm, 75 cfm, 100 cfm, 125 cfm, 150 cfm, 175 cfm, 200 cfm, 225 cfm, 250 cfm, 275 cfm, 300 cfm, 325 cfm, 350 cfm, 375 cfm, 400 cfm and 425 cfm. In other embodiments, the vacuum level and flow rate may be greater than 140 in H2O and 425 cfm, respectively. The vacuum level and flow rate are controlled to be within a range such that debris is pulled away from the web of base material 104 without creating unnecessary friction between the web of base material 104 and the conveying system components. Such vacuum levels and flow rates are, in some embodiments, applicable to all other components of the system using a vacuum.
In another suitable embodiment, one or more of the first brush and the second brush may include a load sensor that measures or monitors the pressure the brush is exerting upon the web of electrode material 802. As shown in
In another suitable embodiment, one or more of the first brush and the second brush are configured to move at least partially in the down-web direction WD at a rate of speed equivalent to the rate of speed of the web of electrode material 802, thus maintaining a substantially zero speed differential between the brush and the web of electrode material 802 in the down-web direction WD.
In yet another suitable embodiment, the brushing station 124 may be equipped with a phase measurement sensor 1016 to determine the phase of the first brush and the second brush. In one such embodiment, the phase sensor may measure the location of a home sensor flag 1018 of the first brush and the second brush. In this embodiment, the phase measurement sensor 1016 determines whether the first and second brushes are within a range of predetermined phase difference, such as 180 degrees out of phase, 90 degrees out of phase or zero degrees out of phase or any other suitable phase difference that allows the production system 100 to function as described herein. As used herein, the “phase” of a brush refers to an angular position of a brush, such that the bristles of two separate brushes would be aligned when “in phase.”
In still another embodiment, an ultrasonic transducer (not shown) may be configured to impart ultrasonic vibrations to one or more of the first and second brushes to facilitate debris removal from the web of electrode material 802.
With further reference to
With reference to
With further reference to
With continued reference to
With In one embodiment, the web of electrode material 802 is held substantially flat during analysis by the inspection device 128, such as by use of application of balanced vacuum or fluid (e.g., air) flow over the opposing sides of the web of electrode material 802. In this embodiment, by having the web of electrode material 802 be flat during inspection, more precise imaging and analysis may be conducted on the web of electrode material 802, and thus higher quality error and defect detection is enabled. In one embodiment, the inspection system may be configured to provide in-line metrology of the web of base material 104 and/or web of electrode material 802. For example, the inspection device 128 may be configured to measure metrics such as web thickness, sizes and shapes of the electrode patterns, and the like while the web is being conveyed in the down-web direction WD. These metrics may be transmitted to the user interface 116 for viewing or memory storage, or otherwise used to adjust production parameters of the production system 100.
In one embodiment, in the event the inspection system determines a defect is present on the web of electrode material 802 (
Upon the processing of the web of base material 104 into the web of electrode material 802, the web of electrode material 802 has a web strength reduction in the down-web direction WD of from 25 percent to 90 percent as compared to the unprocessed web of base material 104. With reference to
In an exemplary embodiment, the cross-web span of the web SW is 3× mm in the cross-web direction and a width WEP of each electrode pattern 800 in the down-web direction WD is × mm. In this embodiment, the reduction in web strength in the down-web direction WD is 33 percent as compared to the unprocessed web of base material 104. The reduction in web strength is calculated as the width WEP divided by the cross-web span SW (i.e., × mm/3× mm=0.33).
In another exemplary embodiment, the cross-web span of the web SW is 1.5× mm in the cross-web direction and a width WEP of each electrode pattern 800 in the down-web direction WD is 1.3× mm. In this embodiment, the reduction in web strength in the down-web direction WD is 87 percent as compared to the unprocessed web of base material 104. The reduction in web strength is calculated as WEP/SW (i.e., 1.3×/1.5×=0.87). Web strength in the down-web direction WD is verified and measured as a breaking strength of the web of electrode material 802 using an electromechanical or hydraulic material tester with at least force feedback, and may include displacement feedback, such as an Instron brand testing machine.
In another exemplary embodiment, there is a strength reduction in the cross-web direction XWD of the web of electrode material 802 as compared to the web of base material 104. In a first exemplary embodiment, the electrode cluster width WEC is 6× mm in the down-web direction WD, the width Wm of the tie bar 614 is × mm in the down-web direction WD and the width WEP of the electrode pattern is × mm in the down-web direction WD and the length LE of the electrode pattern is 1.7× mm in the cross-web direction XWD. In this embodiment, the reduction in strength of the web of electrode material 802 in the cross-web direction XWD is about 77 percent as compared to the unprocessed web of base material 104. In another exemplary embodiment, the electrode cluster length LEC is 10× mm, the width Wm of the tie bar 614 is 0× mm (i.e., no tie bar) and the width WEP of the electrode pattern is 2× mm and the length LE of the electrode pattern is 1.7× mm. In this embodiment, the reduction in strength of the web of electrode material 802 in the cross-web direction XWD is about 92 percent as compared to the unprocessed web of base material 104. Web strength in the cross-web direction XWD is verified and measured as a breaking strength of the web of electrode material 802 using an electromechanical or hydraulic material tester with at least force feedback, and may include displacement feedback, such as an Instron brand testing machine.
With further reference to
In one suitable embodiment, the user interface 116 may include a processor and memory configured to store and execute instructions causing the production system 100 to function as described herein. The user interface 116 may further include a display device, such as a LCD or LED display and a set of controls, or virtual controls, that allow a user to control and adjust parameters of the production system 100, as well as view metrics such as web conveyance speed, tension, number of defects, and any other parameters that allow production system 100 to function as described herein.
In use, with reference to
In one embodiment, the splicing station 110 is used to splice two separate webs together. In this embodiment, a first web of base material 104 is unwound, such that a trailing edge (not shown) of the web of base material 104 is stopped within the splicing station 110, and a leading edge (not shown) of a second web of base material 104 is unwound into the splicing station 110 such that the trailing edge of the first web and the leading edge of the second web are adjacent one another. The user then applies an adhesive, such as an adhesive tape, to join the leading edge of the second web to the trailing edge of the first web to form a seam between the two webs and create a continuous web of base material. Such process may be repeated for numerous webs of base material 104, as dictated by a user.
In one suitable embodiment, upon exiting the splicing station 110, the web of base material 104 is conveyed in the down-web direction WD to the nip roller 112. The nip roller 112 is controlled via user interface 116 to adjust/maintain the speed at which the web of base material 104 is conveyed through the production system 100. The web of base material 104 is pressed against each of the two adjacent rollers 114 of nip roller 112, with enough pressure to allow friction of the rollers to move the web of base material 104, but a low enough pressure to avoid any significant deformation or damage to the web of base material 104.
In one embodiment, during use, the speed of the web of base material 104 is controlled by controlling the rate of rotation of the high friction roller of nip roller 112 via user interface 116. In other embodiments, the production system 100 may include one or more additional nip rollers 122, 132 to facilitate control of the speed of the web of base material 104, and the web of base material is conveyed therethrough. In this embodiment, the speed of the additional nip rollers 122, 132 may be controlled via user interface 116. In use, when multiple nip rollers are used, each of the speed of each of the nip rollers 112, 122, 132 may be set via user interface 116 to the same speed, or different speeds as required, such that the web of base material 104 is conveyed smoothly through production system 100.
In use, in one embodiment, the web of base material is unwound through the dancer 118. In this embodiment, the pair of rollers of the dancer 118 rotates about the central axis thereof, to passively adjust the tension on the web of base material 104.
With further reference to
Use of the production system is further described with additional reference to
With reference to
With further reference to
During use, when using the laser system 120a to make the ablations 404 in the web of base material 104, the power of the laser beam 302 is controlled via user interface 116 to a level that is capable of substantially completely, or completely, removing the coating layer, but will not damage or cut through the current collector layer. In use, the laser beam 302 is controlled, for example via user interface 116, to create the ablations 404 while the web of base material 104 is in motion and being conveyed in down-web direction WD. The laser beam 302 is controlled such that ablations 404 are created on each lateral side of the web of base material 104, as best shown in
With further reference to
In one embodiment of use, the laser system 120a is controlled to cut one or more patterns in the web of base material 104 while the web of base material is over the opening 410. With reference to
With further reference to
With reference to
With further reference to
In use, with reference to
In one suitable embodiment of use, the laser system 120a is configured as a first ablation station. In this embodiment, the laser system 120a is controlled to form the ablations 404, as described above on a first surface of the web of base material 104. Upon exiting laser system 120a, the web of base material is conveyed over idler 108d to flip the web of base material 104 in a manner such that a second surface (opposing the first surface) of the web of base material 104 is positioned for processing by the laser system 120b. In this embodiment, laser system 120b is configured as a second ablation station and uses the fiducial features 602 to ensure alignment of the ablations 404 in the down-web direction WD and cross-web direction XWD. Accordingly, the laser system 120b is controlled to perform a second ablation process on the opposing surface of the web of base material 104, such that ablations 404 on each surface of the web of base material 104 are aligned in the web direction WD and the cross-web direction XWD.
In one embodiment of use, the laser system 120c shown in
With further reference to
With further reference to
In one suitable embodiment of use, a second brush (not shown) is controlled to contact the opposing surface of the web of base material 104. In this embodiment, the second brush, which may be substantially the same as the first brush 1000 is controlled to travel in a direction opposite to the first brush, and suitably 180 degrees out of phase with the first brush. The phase of the first brush and the second brush may be monitored via the position sensor 1016, and an equivalent position sensor of the second brush. In this embodiment, the contact pressure of the bristles of the first brush and the second brush, together, is controlled to be low enough that it does not break, rupture or otherwise cause defects in the electrode patterns, and maintains the electrode patterns as attached to the web of base material 104.
In use, the rate of oscillation of the brush 1000 and the pressure exerted by the bristles 1002 against the surface of the web of base material 104 may be controlled by the user using the user interface 116.
In one embodiment of use, the brushing station 124 is equipped with a vacuum system and controlled to create a vacuum through brush station orifices 1020 to evacuate debris that has been brushed from one or more surfaces of the web of base material 104. In this embodiment, the debris is brushed from the web of base material 104 and falls, or is suctioned through the brush station orifices 1020.
In another suitable embodiment of use, one or more of the first brush and the second brush include a load sensor that is measured or monitored to determine the pressure the brush is exerting upon the web of electrode material 802. In this embodiment, the first brush and the second brush are controlled, via the user interface 116, to maintain a substantially uniform brushing pressure on the web of electrode material 802 based upon variations in brush bristle wear or electrode thickness or surface roughness.
In another suitable embodiment of use, one or more of the first brush and the second brush are controlled to move at least partially in the down-web direction WD at a rate of speed equivalent to the rate of speed of the web of electrode material 802, to maintain a substantially zero speed differential between the brush and the web of electrode material 802 in the down-web direction WD.
In yet another suitable embodiment of use, the brushing station 124 is equipped with a phase measurement sensor 1016 that determines the phase of the first brush and the second brush. In this embodiment, the phase sensor measures the location of the home sensor flag 1018 of the first brush and the second brush. In this embodiment, the phase measurement sensor 1016 determines whether the first and second brushes are within a range of predetermined phase difference, such as 180 degrees out of phase, 90 degrees out of phase or zero degrees out of phase or any other suitable phase difference that allows the production system 100 to function as described herein, and allows for correction thereof or provides an alert to the user via user interface 116 or other alert device that the brushes are not properly phased.
In still another embodiment of use, an ultrasonic transducer (not shown) is activated to impart ultrasonic vibrations to one or more of the first and second brushes to facilitate debris removal from the web of electrode material 802.
With further reference to
With reference to
With further reference to
With additional reference to
In one embodiment of use, the inspection system 128 is used to provide in-line metrology of the web of base material 104 and/or web of electrode material 802. In this embodiment, the inspection device 128 is controlled to measure metrics such as web thickness, sizes and shapes of the electrode patterns, and the like while the web is being conveyed in the machine direction. These metrics are transmitted to the user interface 116 for viewing or memory storage, or otherwise used to adjust production parameters of the production system 100.
In one embodiment of use, if the inspection system determines a defect is present on the web of electrode material 802 (
With further reference to
In one suitable embodiment of use, the web of base material 104 is rewound via a rewind roller 134 together with a web of interleaf material 138, which is unwound via interleaf roller 136 to create a roll of electrodes 140 with layers of the electrodes separated by interleaf material 138. In some embodiments, the web of base material 104 is rewound via the rewind roller 134 without the web of interleaf material 138.
In one embodiment, web of base material 104 has an adhesive tape layer (not shown) adhered to one or both surfaces of the anodically active material layer 508, or cathodically active material layer 512, respectively. In this embodiment, in use, the adhesive layer is removed subsequent to the ablation and cutting (described above) to remove unwanted material or debris.
In one embodiment of use, one or more of the rollers of the conveyor system is not perfectly round, such that the roller has an eccentricity. In such embodiment, the eccentric roller(s) are mapped to determine the radius versus radial position. The laser system 120a-c is then controlled to adjust the laser beam 302 position to account for the eccentricity based upon the mapping of the roller(s).
With reference to
With reference to
As best seen in
As each of the spools of electrode material 1402, 1404 and 1406 are unwound, the unwound web of each of the spools 1402, 1404 and 1406 is controlled to form a catenary curve 1412 prior to engagement with an merge sprocket 1414, for example as shown in
With reference to
After the webs of electrode material from spools 1402, 1404, 1406 are unwound onto the inverted tooth sprocket 1418, each web is then guided and transferred onto pin plate 1424 at transfer location 1426. In one embodiment, tension on the webs of electrode material from spools 1402, 1404, 1406 are controlled such that each web is transferred onto pin plate 1424 at the 6 o'clock position (e.g., vertically downward). The pin plate 1424 includes a series of pins 1428 that are sized and shaped to precisely engage with tractor holes 612 of the webs of electrode material from spools 1402, 1404, 1406 and also the inverted teeth 1420 of inverted tooth sprocket 1418. Accordingly, each of the webs of electrode material from spools 1402, 1404, 1406 is sandwiched between the pin plate 1424 and the inverted tooth sprocket 1418 as it is transferred onto pin plate 1424, while the pins 1428 extend through the tractor holes 612 and into inverted teeth 1420 to facilitate alignment of the web of electrode material from spools 1402, 1404, 1406 onto pin plate 1424.
In one embodiment, the inverted tooth sprocket 1418 is positioned at a suitable height above the pin plate 1424 in the Z-direction, such as from 1 micrometer to 10 millimeters to allow the web to float above the pin plate 1424 before being transferred thereon. In this regard “float” refers to the web having a portion that is not in contact with either the inverted tooth sprocket 1418 or the pin plate 1424, such that the web has some slack which facilitates self-alignment of tractor holes 612 to pins 1428. In embodiments, the height of inverted tooth sprocket 1418 above the pin plate 1424 may be adjustable automatically or manually in order to ensure self-alignment of the tractor holes 612 to pins 1428. The height of inverted tooth sprocket 1418 over pin plate 1424 may also vary depending on which of the webs of electrode material from spools 1402, 1404, 1406 is being transferred to pin plate 1424.
In one embodiment, a nip (i.e., gap) is formed between the inverted tooth sprockets 1418 and the pin plate 1424 such that the web of electrode material from spools 1402, 1404, 1406 has sufficient room to freely float between the inverted tooth sprockets 1418 and the pin plate 1424. In one embodiment, the inverted tooth sprocket 1418 is positioned at a suitable height above the pin plate 1424 in the Z-direction to create a gap of from 1 micrometer to 10 millimeters to allow the web to float above the pin plate 1424 before being transferred thereon. In this regard “float” refers to the web having a portion that is not in contact with either the inverted tooth sprocket 1418 or the pin plate 1424, such that the web has some slack which facilitates self-alignment of tractor holes 612 to pins 1428. In embodiments, the height of inverted tooth sprocket 1418 above the pin plate 1424 may be adjustable automatically or manually in order to ensure self-alignment of the tractor holes 612 to pins 1428. The height of inverted tooth sprocket 1418 over pin plate 1424 may also vary depending on which of the webs of electrode material from spools 1402, 1404, 1406 is being transferred to pin plate 1424. In this embodiment, a small amount of possible misalignment of the respective web of electrode material from spools 1402, 1404, 1406 is reduced or eliminated by allowing the web of electrode material from spools 1402, 1404, 1406 to have a sufficient amount of float (i.e., web that is not in contact with either the inverted tooth sprocket 1418 or the pin plate 1424) to self-adjust and thus align the respective tractor holes 612 to the pin plate 1424. In one suitable embodiment, the slack is sufficient to form an S-shaped curve of the web of electrode material from spools 1402, 1404, 1406 between the inverted tooth sprocket 1418 and the pin plate 1424. It should be appreciated that as each layer of the web of electrode material from spools 1402, 1404, 1406 is placed on to the pin plate 1424, subsequent (i.e., downstream) nips formed between the inverted tooth sprockets 1418 and the pin plate 1424 will increase in size to account for the previous layers of web of electrode material from spools 1402, 1404, 1406 placed thereon. In one suitable embodiment, the nip distance increases by an amount equal to the thickness of the previous layer of web of electrode material from spools 1402, 1404, 1406 placed onto the pin plate 1424.
In one embodiment, as shown in
With reference to
Each layer of the merged material web 1432 has been transferred sequentially, layer by layer, as described in the process above to be vertically aligned. That is, the initial layer in this embodiment, comprised of web of separator material from spool 1406, is transferred to the pin plate 1424 at transfer location 1426. Subsequently, at transfer location 1426A which is located downstream of transfer location 1426, web of cathode material from spool 1402 is transferred atop of the web of separator material from spool 1406. Next, a second layer of separator material from spool 1406 (via a separate spool) is transferred atop of the layer of separator material from spool 1406 at transfer location 1426B, which is downstream of transfer location 1426A. In this embodiment, a layer of anode material web from spool 1404 is transferred atop the second layer of separator material web from spool 1406 at transfer location 1426X. Once all four layers have been stacked, or merged, the four layer laminate web is referred to as merged material web 1432. During the transfer of each layer onto pin plate 1424, the target down-web tension on each layer of merged material web 1432 is zero. In one embodiment, the down-web tension on each layer of merged material web 1432 is determined by the mass of the web from each spool 1402, 1404, 1406, respectively, and the amount of sag of such web between merge sprocket 1414 and the pins 1428 of pin plate 1424.
During the transfer of each layer, it should be appreciated that the pins 1428 of pin plate 1424 are sized to extend through each layer of material and into inverted teeth 1420 of inverted tooth sprocket 1418 to maintain alignment of each layer with respect to one another. At each of the transfer locations, a nip (i.e., gap) is formed at transfer location 1426 between the respective inverted tooth sprocket 1418 and pin plate 1424, which is set to a fixed gap distance of from 100 to 1000 μm over the web. In one embodiment, the nip is set to approximately 3 times the thickness of the web. For example, if the thickness of the web in the Z-direction is 100 microns, the nip gap will be approximately 300 microns in the Z-direction. It should be appreciated that the actual gap distance between the respective inverted tooth sprocket 1418 and pin plate 1424 is increased at each downstream transfer location 1426 to account for the added thickness of each previous layer that has been transferred onto the pin plate 1424. In one embodiment, the increase in gap distance at each subsequent downstream transfer location is approximately equivalent to the height of the added layer in the Z-direction. In one embodiment, the nip gap is about three times the height of the merged material web at the respective transfer location 1426. As shown in
A cross sectional view 1500 of one embodiment of merged material web 1432 is shown in
In some embodiments, the pin plate 1424 includes a population of individual separate pin plates (each similar to pin plate 1424) that each are abutted and indexed to one another to form a continuous stream of pin plates. In this embodiment, it is important that the individual pin plates be precisely positioned with respect to one another, such that proper registration of the layers of merged material web 1432 is maintained as each of the layers are transferred onto the pin plates. Accordingly, in some embodiments, each pin plate 1424 may be held by a jig or other alignment device, such as a pin, magnet, protrusion or the like to maintain proper registration of the pin plates 1424. The pin plates 1424 are conveyed in the web direction via a conveyor mechanism 1436, which is controlled to travel at the same speed as inverted tooth sprocket 1418, such that the layers of merged material web 1432 are properly aligned to the pins 1428 of pin plates 1424. In one embodiment, the engagement of pins 1428 with inverted teeth 1420 are what propel pin plates 1424 in the down-web direction WD. Accordingly, in such embodiment, proper speed is maintained between pin plates 1424 and inverted tooth sprocket 1418.
In one embodiment, at one or more of transfer locations 1426, 1426A-X, an electrode defect sensor 1434 is positioned such that the web of electrode material from spools 1402, 1404 and 1406 pass adjacent to the defect sensor 1434. It is noted that as used herein, 1426X is used to refer to any number of additional transfer locations as described herein. The defect sensor 1434 is configured to detect defects in the web of electrode material from spools 1402, 1404 and 1406. For example, defect sensor 1434 may be configured to detect missing electrodes from the web, misaligned or missing tractor holes 612, fiducial features 602, ablations, cuts, perforations or other weakened areas in the web of electrode material from spools 1402, 1404 and 1406. In the event the defect sensor 1434 detects a defect in the web of electrode material from spools 1402, 1404 and 1406, the web may be marked using a marking device collocated with the defect sensor 1434 to indicate the defect. The marking of the defect may be used in subsequent process steps to ensure that the defective portion of the web of electrode material from spools 1402, 1404 and 1406 is not used in the stacking phase, further described below, or is otherwise disposed of prior to becoming part of a stacked cell 1704.
With reference to
Accordingly, in order to remediate the curl, the tensioning section 1438 may include at least one of counter rotating brushes 1440 (
In one embodiment, the tensioning section includes a deionizer device 1447 configured to reduce or eliminate the static electrical charge on the web of electrode material from spools 1402, 1404 and 1406. In such embodiment, the deionizer device 1447 is placed upstream, just prior to, the vacuum tensioner 1442 and counter rotating brushes 1440. The deionizer device 1447 is configured to neutralize an electrical charge of components, such as the vacuum tensioner 1442, which may be formed from plastic pipe, such as PVC, in some embodiments. For example, if a deionizer is not used, when the separator material from spool 1406 passes over the vacuum tensioner, or when small particles are carried by airflow through the vacuum tensioner, it may build up a static electrical charge on the vacuum tensioner 1442. Accordingly, the deionizer device 1447 may be used to neutralize the electrical charge on the vacuum tensioner 1442, thus allowing the web of electrode material from spools 1402, 1404 and 1406 to pass thereby without being electrically attracted to the vacuum tensioner 1442. It should be noted that although the deionizer device has been described with respect to vacuum tensioner 1442, one or more deionizer devices 1447 may be used on any component within the system that is affected by electrical charge and benefits from charge neutralization, such as any component that is in contact with or close proximity to webs of electrode material from spools 1402, 1404 and 1406. In some embodiments, the deionizer device 1447 is a DC ionizing bar. In some embodiments, the deionizer device 1447 is capable of pulsed DC ionization for short range applications, such as from 20 mm to 200 mm. In some embodiments, the frequency of the pulses may be controlled, automatically, or by a user, to be set from 1 Hz to 20 Hz in order to adjust the effect of the deionizer device 1447 on the affected component. In some embodiments, the deionizer device 1447 is configured with metal pins, such as titanium pins or the like, that are used as ionizer emitters. Such pins may have an output of from −3 kV to +7.5 kV in pulsed DC mode, which facilitates allowing positive to negative charged ion ratios of from 80:20 to 20:80. Accordingly, the deionizer device 1447 In other embodiments the order of the deionizer device 1447, vacuum tensioner 1442 and counter rotating brushes 1440 may vary. In another embodiment, electrical charge buildup may be prevented by grounding the affected component. In this embodiment, a grounding strap or grounding wire (not shown) is electrically connected to the affected device, such as vacuum tensioner 1442, to prevent electrical charge buildup by providing the electrical charge to have a path to ground. In yet another embodiment, electrical charge buildup of components may be prevented by coating the affected device with a conductive coating to prevent charge buildup.
In one suitable embodiment, the rotational speed of the counter rotating brushes 1440 is kept sufficiently low to reduce or eliminate excessive wear or heat build-up caused by the friction of counter rotating brushes 1440 in contact with the web of electrode material 1402, 1404 and 1406. In one embodiment, the counter rotating brushes 1440 are configured to smooth or otherwise reduce wrinkles present in the web of electrode material from spools 1402, 1404 and 1406. In one embodiment, the counter rotating brushes 1440 are configured to reduce or eliminate micro-wrinkles in the web of electrode material 1402, 1404 and 1406. In such embodiment, the micro-wrinkles are wrinkles in the web that are too small to be removed by the deionizer 1447 or the vacuum tensioner 1442. In one such embodiment, the micro-wrinkles are defined as wrinkles that are approximately twenty percent the magnitude of macro-wrinkles that are removed by the deionizer 1447 or the vacuum tensioner 1442. In one suitable example, if a macro-level wrinkle is approximately 100 mm in magnitude in the Z-direction, micro-wrinkles will have a magnitude of 20 mm or less in the Z-direction. In other embodiments, macro-wrinkles may have a magnitude of between 1 mm to 250 mm and micro-wrinkles may have a magnitude of from 0.2 mm to about 50 mm.
In another embodiment, in addition to or alternative to the counter rotating brushes 1440, the material tensioning section 1438 includes a vacuum tensioner 1442, which includes a plurality of vacuum orifices 1444 located on a surface of the vacuum tensioner 1442 adjacent to the web of electrode material from spools 1402, 1404 and 1406. In this embodiment, a vacuum is pulled through the vacuum tensioner 1442, which creates a suction through vacuum orifices 1444. The vacuum tensioner 1442 is positioned at an angle αvac (
With further reference to
In one embodiment, the counter rotating brushes 1440 are located, in a downstream location in the web direction WD of vacuum tensioner 1442. However, in other embodiments, counter rotating brushes are co-located with, or upstream of, vacuum tensioner 1442. In one embodiment, each of the transfer locations 1426, 1426A-X, include counter rotating brushes 1440 and a vacuum tensioner. In another embodiment, only transfer stations that transfer web of separator material include the counter rotating brushes 1440, but all transfer stations include a vacuum tensioner 1442.
With reference to
With reference to
With further reference to
With reference to
With additional reference to
With reference to
As shown in
In embodiments, the punch head 2016 is made of a metal or metal alloy, such as stainless steel, aluminum, titanium, steel, other metals and alloys thereof In other embodiments, the punch head 2016 may be made from any material that allows the system to function as described herein, such as plastics, carbon fiber, wood, and the like. The punch head should be of sufficient strength and stiffness that it does not deform as it applies the force to the electrode sub-unit 2018. With reference to
In one embodiment, the punch head 2016 applies a Z-direction force to the electrode sub-unit 2018 which transmits such force to the movable platform 2034, which exerts an opposing force thereto (e.g., by controlling the stepper motor to create a holding torque). In one embodiment, these opposing forces cause a slight compression in the electrode sub-unit that facilitates overcoming the static friction between the alignment pins and the fiducial features 602 of the electrode sub-unit 2018, which facilitates maintaining parallelism of the electrode sub-unit 2018 with an ideal plane that is perpendicular to the alignment pins 2012. In one embodiment, the force exerted by the punch head 2016 to the movable platform 2034 causes the movable platform 2034 to move in the Z-direction a distance equal to the height of the electrode sub-unit 2018, thus rupturing the weakened region along the path formed by lengthwise edge cuts 600 and perforations 608, and thus ready to accept the next electrode sub-unit 2018. In another embodiment, the movable platform 2034 may be controlled to move away from the punch head 2016 in the Z-direction, for example by use of the stepper motor, a predetermined distance equal to the z-direction dimension of an electrode sub-unit 2018 after each electrode sub-unit 2018 has been punched by punch head 2016. The moveable platform 2034 thus facilitates maintaining the electrode sub-units perpendicular to the alignment pins 2012 during the punching operation.
As shown in
In one embodiment, prior to initiating a punching operation, the high volume stacking system 2000 verifies that there are no defects (as determined by the electrode defect sensor 1434) in an electrode sub-unit 2018, in the event a defect is detected, the system is controlled to avoid punching and stacking of the defective electrode sub-unit 2018. In one embodiment, where multiple receiving units 2010 and corresponding punch heads 2016 are used, if a defect is found on one of the electrode sub-units 2018, all of the receiving units 2010 and corresponding punch heads 2016 are controlled to skip the punching and stacking operation, and the merged material web 1432 is conveyed forward to a position such that all receiving units 2010 and corresponding punch heads 2016 are aligned under defect-free electrode sub-units 2018.
In one embodiment, in order to separate each of the electrode-sub units 2018 from the merged material web 1432, the punch head 2016 is moved in the Z-direction toward the merged material web 1432, for example to within about 0.15 mm to about 0.50 mm from the surface of the merged material web. The alignment pins 2012 of the receiving jig are controlled to move in the Z-direction toward the opposing surface of the merged material web 1432. Alignment of the alignment pins 2012 and punch head 2016 may be verified using optical sensor 1902. If it is determined that the alignment pins 2012 are not properly aligned with the punch head 2016, one or more of the punch head 2016, receiving unit 2010 or merged material web 1432 may be moved in the web direction WD until satisfactory alignment is achieved. In such embodiment, one or more of receiving unit 2010 and punch head 2016 may be configured for translation in the web direction via a motorized carriage assembly (not shown). Once satisfactory alignment of alignment pins 2012 and punch head 2016 are achieved, the receiving unit is moved in the Z-direction such that the alignment pins 2012 move through the fiducial features 602 and into corresponding punch head holes 2020 in the punch head 2016. In one embodiment, the alignment pins 2012 enter at least 2 mm into the punch head holes 2020. In one embodiment, the punch head holes 2020 are sized and shaped to closely match the outer diameter of the alignment pins 2012 to minimize any shifting or misalignment during the punching and stacking operation.
Next, the punch head 2016 is controlled to move in the Z-direction toward receiving unit 2010, for example at least 5 mm past the opposing surface of the merged material web 1432. As the punch head 2016 moves, the electrode sub-unit 2018 is separated from the merged material web 1432 along a weakened region forming an outer perimeter of the electrode sub-unit 2018. For example, the weakened region may comprise the path along lengthwise edge cuts 600 and perforations 608 (
After the electrode sub-unit has been separated from the merged material web 1432, the punch head 2016 moves in the Z direction away from the receiving unit 2010 and the receiving unit moves in the Z direction away from the punch head 2016. In one embodiment, both the punch head 2016 and the receiving unit 2010 both move simultaneously. In other embodiments, each of the punch head 2016 and the receiving unit 2010 are controlled to move sequentially. In one embodiment, each of the punch head 2016 and the receiving unit 2010 are moved to a distance of about 0.5 mm away from the respective surfaces of the merged material web 1432 in the Z-direction.
It should be appreciated that although
After the electrode sub-unit has been separated from the merged material web 1432, the downstream remaining web is referred to as spent web 2022, which is conveyed in the web direction WD using a de-merge sprocket 2024 (
In one embodiment, the high volume stacking system 2000 includes one or more cross-web belt tensioners 2028. The cross-web belt tensioners 2028 are configured to engage with a secondary set of teeth 2032 (
In some embodiments, if sufficient down-web tension is applied to the merged material web 1432 by synchronization sprockets 2006, the merged material web 1432 may stretch in the down-web direction, causing the fiducial features 602 to be spaced further apart in the down-web direction than intended. In such embodiments, the toothed belt 2002 is controlled to reduce its speed, which causes a corresponding reduction in the down-web tension on the merged material web 1432 in the web direction WD, or alternatively the toothed belt 2002 may be controlled to increase speed which causes a corresponding increase in the tension on the merged material web 1432 in the web direction WD.
During the punching operation, the electrode sub-unit 2018 is configured to separate from the merged material web 1432 in a predetermined manner defined by the strength of the outer perforations 608 and the inner perforations 610 (
In one embodiment, a predetermined number of electrode sub-units 2018 are stacked on receiving unit 2010 to form a multi-unit electrode stack 2030 (
After the perforations 610 have ruptured, the multi-unit electrode stack 2030 proceeds to a tab welding station to weld bus bars 1700 and 1702 to the ablations 404 to form stacked cell 1704. Prior to welding, the bus bars 1700, 1702 are placed through the bus bar openings 1608 of the respective electrode. In one embodiment, once the bus bars 1700, 1702 have been placed through the bus bar openings 1608, the ablations 404 are folded down toward bus bars 1700, 1702 respectively, prior to welding. In this embodiment, bus bar 1700 is a copper bus bar and is welded to the ablations 404 (anode tabs) of the anode current collector layer 506, and bus bar 1702 is an aluminum bus bar and is welded to the ablations 404 (cathode tabs) of the cathode current collector layer 510. However, in other embodiments, the bus bars 1700 and 1702 may be any suitable conductive material to allow battery 1804 to function as described herein. The welds may be made using a laser welder, friction welding, ultrasonic welding or any suitable welding method for welding bus bars 1700, 1702 to the electrode tabs 520. In one embodiment, each of the bus bars 1700 and 1702 are in electrical contact with all of the electrode tabs 520 for the anode and cathode, respectively.
Upon formation of the stacked cell 1704, the stacked cell proceeds to a packaging station 1800. At the packaging station 1800, the stacked cell 1704 is coated with an insulating packaging material, such as a multi-layer aluminum polymer material, plastic, or the like, to form a battery package 1802. In one embodiment, the battery package 1802 is evacuated using a vacuum and filled through an opening (not shown) with an electrolyte material. The insulating packaging material may be sealed around stacked cell 1704 using a heat seal, laser weld, adhesive or any suitable sealing method. The bus bars 1700 and 1702 remain exposed, and are not covered by battery package 1802 to allow a user to connect the bus bars to a device to be powered, or to a battery charger. Once the battery package 1802 is placed on stacked cell 1704, it defines a completed battery 1804. In this embodiment, the completed battery is a 3-D lithium ion type battery. In other embodiments, the completed battery may be any battery type suitable for production using the devices and methods described herein. In some embodiments, the battery 1804 comprises one or more electrode sub-units 2900a-f, or unit cells 3300, as described further herein.
In one embodiment, each member of the anode population has a bottom, a top, and a longitudinal axis AE (
The length (LE) of the members of the anode population members will vary depending upon the energy storage device and its intended use. In general, however, the members of the anode populations will typically have a length (LE) in the range of about 5 mm to about 500 mm. For example, in one such embodiment, the members of the anode population have a length (LE) of about 10 mm to about 250 mm. By way of further example, in one such embodiment the members of the anode population have a length (LE) of about 25 mm to about 100 mm.
The width (WE) of the members of the anode population will also vary depending upon the energy storage device and its intended use. In general, however, each member of the anode population will typically have a width (WE) within the range of about 0.01 mm to 2.5 mm. For example, in one embodiment, the width (WE) of each member of the anode population will be in the range of about 0.025 mm to about 2 mm. By way of further example, in one embodiment, the width (WE) of each member of the anode population will be in the range of about 0.05 mm to about 1 mm.
The height (HE) of the members of the anode population will also vary depending upon the energy storage device and its intended use. In general, however, members of the anode population will typically have a height (HE) within the range of about 0.05 mm to about 10 mm. For example, in one embodiment, the height (HE) of each member of the anode population will be in the range of about 0.05 mm to about 5 mm. By way of further example, in one embodiment, the height (HE) of each member of the anode population will be in the range of about 0.1 mm to about 1 mm. According to one embodiment, the members of the anode population include one or more first electrode members having a first height, and one or more second electrode members having a second height that is other than the first. 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 an electrode assembly (e.g., multi-layer sub-stack 1501 (
In general, members of the anode population have a length (LE) that is substantially greater than each of its width (WE) and its height (HE). For example, in one embodiment, the ratio of LE to each of WE and HE is at least 5:1, respectively (that is, the ratio of LE to WE is at least 5:1, respectively and the ratio of LE to HE is at least 5:1, respectively), for each member of the anode population. By way of further example, in one embodiment the ratio of LE to each of WE and HE is at least 10:1. By way of further example, in one embodiment, the ratio of LE to each of WE and HE is at least 15:1. By way of further example, in one embodiment, the ratio of LE to each of WE and HE is at least 20:1, for each member of the anode population.
In one embodiment, the ratio of the height (HE) to the width (WE) of the members of the anode population is at least 0.4:1, respectively. For example, in one embodiment, the ratio of HE to WE will be at least 2:1, respectively, for each member of the anode population. By way of further example, in one embodiment the ratio of HE to WE will be at least 10:1, respectively. By way of further example, in one embodiment the ratio of HE to WE will be at least 20:1, respectively. Typically, however, the ratio of HE to WE will generally be less than 1,000:1, respectively. For example, in one embodiment the ratio of HE to WE will be less than 500:1, respectively. By way of further example, in one embodiment the ratio of HE to WE will be less than 100:1, respectively. By way of further example, in one embodiment the ratio of HE to WE will be less than 10:1, respectively. By way of further example, in one embodiment the ratio of HE to WE will be in the range of about 2:1 to about 100:1, respectively, for each member of the anode population.
In one embodiment, a member of the cathode population is formed from the web of base material 104 being cathode material 504. Referring now to
The length (LCE) of the members of the cathode population will vary depending upon the energy storage device and its intended use. In general, however, each member of the cathode population will typically have a length (LCE) in the range of about 5 mm to about 500 mm. For example, in one such embodiment, each member of the cathode population has a length (LCE) of about 10 mm to about 250 mm. By way of further example, in one such embodiment each member of the cathode population has a length (LCE) of about 25 mm to about 100 mm.
The width (WCE) of the members of the cathode population will also vary depending upon the energy storage device and its intended use. In general, however, members of the cathode population will typically have a width (WCE) within the range of about 0.01 mm to 2.5 mm. For example, in one embodiment, the width (WCE) of each member of the cathode population will be in the range of about 0.025 mm to about 2 mm. By way of further example, in one embodiment, the width (WCE) of each member of the cathode population will be in the range of about 0.05 mm to about 1 mm.
The height (HCE) of the members of the cathode population will also vary depending upon the energy storage device and its intended use. In general, however, members of the cathode population will typically have a height (HCE) within the range of about 0.05 mm to about 10 mm. For example, in one embodiment, the height (HCE) of each member of the cathode population will be in the range of about 0.05 mm to about 5 mm. By way of further example, in one embodiment, the height (HCE) of each member of the cathode population will be in the range of about 0.1 mm to about 1 mm. According to one embodiment, the members of the cathode population include one or more first cathode members having a first height, and one or more second cathode members having a second height that is other than the first. In yet another embodiment, 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 an electrode assembly, such as an electrode assembly shape having a different heights along one or more of the longitudinal and/or transverse axis, and/or to provide predetermined performance characteristics for the secondary battery.
In general, each member of the cathode population has a length (LCE) that is substantially greater than width (WCE) and substantially greater than its height (HCE). For example, in one embodiment, 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 member of the cathode population. By way of further example, in one embodiment the ratio of LCE to each of WCE and HCE is at least 10:1 for each member of the cathode population. By way of further example, in one embodiment, the ratio of LCE to each of WCE and HCE is at least 15:1 for each member of the cathode population. By way of further example, in one embodiment, the ratio of LCE to each of WCE and HCE is at least 20:1 for each member of the cathode population.
In one embodiment, the ratio of the height (HCE) to the width (WCE) of the members of the cathode population is at least 0.4:1, respectively. For example, in one embodiment, the ratio of HCE to WCE will be at least 2:1, respectively, for each member of the cathode population. By way of further example, in one embodiment the ratio of HCE to WCE will be at least 10:1, respectively, for each member of the cathode population. By way of further example, in one embodiment the ratio of HCE to WCE will be at least 20:1, respectively, for each member of the cathode population. Typically, however, the ratio of HCE to WCE will generally be less than 1,000:1, respectively, for each member of the anode population. For example, in one embodiment the ratio of HCE to WCE will be less than 500:1, respectively, for each member of the cathode population. By way of further example, in one embodiment the ratio of HCE to WCE will be less than 100:1, respectively. By way of further example, in one embodiment the ratio of HCE to WCE will be less than 10:1, respectively. By way of further example, in one embodiment the ratio of HCE to WM will be in the range of about 2:1 to about 100:1, respectively, for each member of the cathode population.
In one embodiment, anode current collector 506 also has an electrical conductance that is substantially greater than the electrical conductance of the negative electrode active material layer. For example, in one embodiment the ratio of the electrical conductance of anode current collector 506 to the electrical conductance of the negative electrode active material layer is at least 100:1 when there is an applied current to store energy in the device or an applied load to discharge the device. By way of further example, in some embodiments the ratio of the electrical conductance of anode current collector 506 to the electrical conductance of the negative electrode active material layer is at least 500:1 when there is an applied current to store energy in the device or an applied load to discharge the device. By way of further example, in some embodiments the ratio of the electrical conductance of anode current collector 506 to the electrical conductance of the negative electrode active material layer is at least 1000:1 when there is an applied current to store energy in the device or an applied load to discharge the device. By way of further example, in some embodiments the ratio of the electrical conductance of anode current collector 506 to the electrical conductance of the negative electrode active material layer is at least 5000:1 when there is an applied current to store energy in the device or an applied load to discharge the device. By way of further example, in some embodiments the ratio of the electrical conductance of anode current collector 506 to the electrical conductance of the negative electrode active material layer is at least 10,000:1 when there is an applied current to store energy in the device or an applied load to discharge the device.
In general, the cathode current collector layer 510 may comprise 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 (see “Current collectors for positive electrodes of lithium-based batteries” by A. H. Whitehead and M. Schreiber, Journal of the Electrochemical Society, 152(11) A2105-A2113 (2005)). By way of further example, in one embodiment, cathode current collector layer 510 comprises gold or an alloy thereof such as gold silicide. By way of further example, in one embodiment, cathode current collector layer 510 comprises nickel or an alloy thereof such as nickel silicide.
Spacers
With reference to
In general, the spacer members comprise a spacer material comprising a polymeric material, a composite such as adhesive tape, electrode current collector, electrode active material, counter-electrode active material, counter-electrode current collector, separator material, or a material that is chemically inert (in the battery environment). For example, in one embodiment the spacer members comprise an anodically active material having the capacity to accept carrier ions; in this embodiment, it is generally preferred that the anodically active material comprise graphite, graphene, or other anodically active material having a capacity for carrier ions that is less than one mole of carrier ion per mole of spacer material. By way of further example, in one embodiment the spacer members comprise a cathodically active material having the capacity to accept carrier ions. By way of further example, in one embodiment the spacer members may comprise a polymeric material (e.g., a homopolymer, copolymer or polymer blend); in such embodiments, the spacer member may comprise a fluoropolymer derived from monomers containing vinylidene fluoride, hexafluoropropylene, tetrafluoropropene, a polyolefin such as polyethylene, polypropylene, or polybutene, ethylene-diene-propene terpolymer, polystyrene, polymethyl methacrylate, polyethylene glycol, polyvinyl acetate, polyvinyl butyral, polyacetal, and polyethyleneglycol diacrylate, methyl cellulose, carboxymethyl cellulose, styrene rubber, butadiene rubber, styrene-butadiene rubber, isoprene rubber, polyacrylamide, polyvinyl ether, polyacrylic acid, polymethacrylic acid, polyacrylonitrile, polyvinylidene fluoride polyacrylonitrile, polyethylene oxide, acrylates, styrenes, epoxies, silicones, polyvinylidene fluoride-co-hexafluoropropylene, polyvinylidene fluoride-co-trichloroethylene, polymethylmethacrylate, polyacrylonitrile, polyvinylpyrrolidone, polyvinyl acetate, polyethylene-co-vinyl acetate, polyethylene oxide, cellulose acetate, cellulose acetate butyrate, cellulose acetate propionate, cyanoethylpullulan, cyanoethyl polyvinylalcohol, cyanoethylcellulose, cyanoethylsucrose, pullulan, carboxymetyl cellulose, acrylonitrile-styrene-butadiene copolymer, polyimide, polyvinylidene fluoride-hexafluoro propylene, polyvinylidene fluoride-trichloroethylene, polymethyl methacrylate, polyacrylonitrile, polyvinyl pyrrolidone, polyvinyl acetate, ethylene vinyl acetate copolymer, polyethylene oxide, cellulose acetate, cellulose acetate butyrate, cellulose acetate propionate, cyanoethyl pullulan, cyanoethyl polyvinyl alcohol, cyanoethyl cellulose, cyanoethyl sucrose, pullulan, carboxyl methyl cellulose, acrylonitrile styrene butadiene copolymer, polyimide, polyethylene terephthalate, polybutylene terephthalate, polyester, polyacetal, polyamide, polyetheretherketone, polyether sulfone, polyphenylene oxide, polyphenylene sulfide, polyethylene naphthalene, and/or combinations or a copolymer thereof.
In one embodiment, the spacer members are in the form of an adhesive tape having a base and an adhesive layer provided on one surface of the base. The composition of the adhesive tape base is not particularly limited, and various bases known to be usable for the adhesive tape can be used. In general, plastic films are preferred and specific examples include polyolefin films such as a polyethylene, polypropylene, polyethylene terephthalate, a polybutylene terephthalate, polyphenylene sulfide, polyimide, or polyamide film. In some embodiments, polyolefin, polyethylene terephthalate and polyimide films may be preferred in terms of heat resistance and chemical resistance suitable for the battery application. The adhesive tape base may have a thickness in the range of about 4 to 200 μm, e.g., in the range of 6 to 150 μm, or even about 25 to 100 μm. The adhesive constituting the adhesive layer of the adhesive tape may comprise, for example, a rubber-based adhesive, an acrylic adhesive, a silicone-based adhesive or a combination thereof.
In some embodiments, the spacer members 2700a-d may be continuous (e.g., a continuous tape or ribbon) in the Z-Axis direction, can be discontinuous (e.g., a series of discontinuous strips, protrusions or the like) in the Z-Axis or X-Axis directions (or both), or can be porous (e.g., having void space within the volume of the spacer members 2700a-d.
In one embodiment, the spacer members 2700a-d may be applied to the web of base material 104 prior to any or all of the splicing, cutting or perforating operations described herein. In other embodiments, the spacer members 2700a,b are applied after one or more of the splicing, cutting or perforating operations described herein. In embodiments where the spacer members 2700a-d are applied prior to splicing, cutting or perforating operations described herein, the spacer member will also have one or more of the splicing, cutting or perforating operations described herein, such as to cut through holes 2704 therein (
In one embodiment, the width Ws1 is greater than or equal to 50 percent of the cathodically active material layer 512 width in the Y-Axis direction. In yet another embodiment, the width Ws1 is greater than or equal to 50 percent of the cathodically active material layer 512 plus the width of the cathode current collector layer 510 width in the Y-Axis direction. In another embodiment, the width Ws1 is greater than or equal to 50 percent of the cathodically active material layer 512 plus a width of the expansion gap 3002 WG in the Y-Axis direction.
In one embodiment, the spacer members 2700a-d are a tape material having an adhesive applied to first surface 2720 of the spacer member that secures the spacer members 2700a-d to the web of base material 104. In some embodiments, the adhesive is a strong adhesive that permanently secures the spacer members 2700a-d to the web of base material 104. In other embodiments, the adhesive is a weak adhesive that removably secures the spacer members 2700a-d to the web of base material 104. As used herein, the strong adhesive is defined as an adhesive having sufficient strength wherein the spacer member 2700a-d cannot be removed from the web of base material 104 without damage to one or both of the spacer members 2700a,b or 2700c,d and/or the web of base material 104. As used herein, a weak adhesive is defined as having sufficient strength to adhere the spacer members 2700a-d to the web of base material 104 but allow the spacer members to be removed without causing material damage to at least the web of base material 104. In embodiments using the weak adhesive, when removed it is preferred that the adhesive layer does not leave any residue on the web of base material 104. In another embodiment, the spacer member has an adhesive applied to both a first surface 2720 and a second opposing surface 2721. In this embodiment, a release layer may be applied to second surface 2021 that is removed before adhering to an adjacent layer. In yet other embodiments, the spacer members 2700a-d are applied without being adhered to any layer. In another embodiment, the spacer members 2700a-d are applied using a printing process, such as a 3-D printing process. In still another embodiment, the spacer members 2700a-d are applied by melting or welding the spacer members 2700a-d to the respective layer.
In yet another embodiment, the spacer members may be added during one or more of the merging and stacking operations as described herein. For example, in one embodiment, an additional spool of spacer member material is unwound and merged into the merged material web at the desired location between adjacent layers of the merged material web. In this embodiment, the spacer members may form part of a web of material that is merged in a manner similar to the webs from spools of electrode materials 1402, 1404 and 1406. In yet another embodiment, the spacer members may form two separate ribbons, one for each of 2700a and 2700b, wherein each of the ribbons is conveyed using its own tractor hole and merged using a process similar to that described with merging the webs from spools of electrode materials 1402, 1404 and 1406.
In yet another embodiment, with reference to
In one embodiment, the spacer members 2700a-d are positioned such that the entirety of the spacer members 2700a-d are inside, in a cross-web direction toward an electrode center point 2702, of an outer boundary defined by the inner perforations 608. In other embodiments, the spacer members 2700a,b may be positioned partially overlapping the inner perforations 608 or outer perforations 610. With respect to the use and placement of the spacer members 2700a-d, such may similarly be applied to one or more of webs of electrode material 1402, 1404, and 1406 or anode current collector layer 506, anodically active material layer 508, separator 500, cathodically active material layer 512 and cathode current collector 510 in a manner substantially similar to that described above with respect to web of base material 104.
Use of the spacer members 2700a-d will now be described with respect to stacked electrode sub-units 2900a-d and stacked cells 2904. Electrode sub-units 2900a-d are similar to electrode sub-units 2018, except electrode sub-units 2900a-e include one or more spacer members 2700a-d. Stacked cell 2904 is similar to stacked cell 1704, except stacked cell 2904 is assembled using one or more of electrode sub units 2900a-d. The stacked cell 2904 may include one or more electrode sub-units 2900a-e, such as from 1 to 100 electrode sub-units 2900a-d. In other embodiments, stacked cell 2904 may include any number of electrode sub-units 2900a-d as may be desired for a particular application.
Electrode sub-units 2900a-f are now described with reference to
In some embodiments, the location at which the spacer members 2700a-d are positioned in the cross-web direction is referred to as the margins 2701a,b. The margin 2701a,b is defined as extending from the outside edge 2750 of the web (or electrode sub-unit, or unit cell) to the inside edge 2752 of the spacer member 2700a-d. This region of the electrode layers corresponding to the margins 2701a,b of the counter-electrode (e.g., comprising the cathode current collector layer 510 and the cathodically active material layer 512) and/or the electrode (e.g., comprising the anode current collector 506 and the anodically active material layer 508) may be referred to as the flank portions of the counter-electrode or electrode. In other words, the flank portions (3027a,b) (See
In some embodiments, the margins 2701a,b (e.g., first edge margin 2701a and second edge margin 2701b) includes for a unit cell, in the cross-web direction, the anode (e.g., electrode) current collector layer 506, the separator layer 500, and the cathode (e.g., counter-electrode) current collector layer 510, and spacer member 2700a-d (e.g., a tape spacer), each of the tape spacers being adhered to at least one of (i) the electrode current collector, (ii) the electrode layer, (iii) the separator, and (iv) the counter-electrode current collector. The main body 2725 is the portion of the web, electrode sub-unit, or unit cell proximal of the spacer member 2700a-d, in a cross-web direction, to a center of the electrode sub-unit 2900a-d (i.e., the area between margins 2701a and 2701b. The main body 2725 includes, in the Z-direction, one or more of each of the anode (e.g., electrode) current collector layer 506, anodically active material layer 508, the separator layer 500, the cathode (e.g., counter-electrode) current collector layer 510, cathodically active material layer 512 and an expansion gap 3002, but no spacer member 2700a-d. In another embodiment, each electrode sub-unit 2900b includes a cathode (counter-electrode) current collector layer 510, a cathodically active layer (counter-electrode) 512, separator layer 500, anodically active material layer (electrode) 508, anode current collector layer 506 and spacer members 2700a,b. In this embodiment, the spacer members 2700a,b are positioned directly adjacent separator layer 500 in a manner such that separator layer is folded/bent (e.g., conformed) at each distal end 3000a,b (in the cross-web direction) to have an “L-shape” 3008 to be in contact with cathode current collector layer 510. In this embodiment, the spacer members 2700a,b extend from a lower boundary 3006 of anode current collector 506 to an region vertically aligned with the upper boundary 3004 of the cathodically active material layer 512. In this embodiment, the spacer member 2700a,b are each of a sufficient width Wo that an expansion gap 3002 is defined between separator layer 500 and anodically active material layer 508. The width Wo is controlled such that the expansion gap 3002 has a height WG as specified. In embodiments, the width WG is set to be from 0 micrometer (e.g., no gap) to 1000 micrometers, such as 1 μm, 2 μm, 5 μm, 10 μm, 20 μm, 50 μm, 100 μm, 200 μm, 300 μm, 400 μm, 500 μm, 600 μm, 700 μm, 800 μm, 900 μm or 1000 μm or greater.
In some embodiments, the spacer members 2700a-d have a length Ls1 in the X-Axis direction. The length Ls1 is equivalent to an offset in the X-Axis direction of the anodically active material layer and/or the cathodically active material layer that has been ablated or otherwise removed (e.g., from distal ends 3015a, 3015b and 3021a, 3021b as shown in
In some embodiments, the flank portions 3027a,b of the counter electrode layer (cathode current collector 510 and cathodically active material layer 512 together) have a width in the Y-axis direction that is less than or equal to 50 percent of the width of the central portion of the counter electrode, such as less than 40 percent the width of the central portion, or such as less than 20 percent the width of the central portion, or such as less than 10 percent the width of the central portion.
The volume occupied by the expansion gap 3002 may also be referred to as a void fraction, and expressed as a ratio of open space (i.e., the void) to active material within the stacked cell 2904. A higher void fraction, or larger expansion gap 3002, is provided by having an increased width WG facilitated by spacer members 2700a,b with increased width Ws1. As a general rule, a larger expansion gap 3002 provides the stacked cell for more room for the active materials, which in some embodiments, may swell during discharge or charging operations. However, in some embodiments, increased expansion gap 3002 size comes at the expense of battery capacity, since the expansion gap 3002 and the tape spacers 2700a,b do not constitute active material and thus do not add to the theoretical battery capacity for the stacked cell 2904.
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In some embodiments, for example as shown in
Additional description of electrode sub-units 2900a-d are now described with reference to
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It should be appreciated that a stacked cell may include any number of electrode sub-units 2900a-d in a repeated, stacked arrangement. When stacked, the electrode sub-units 2900a-d are stacked such that a separator layer 500 is always between adjacent anodically active material layers 508 and cathodically active material layers 512 in order to prevent short circuiting of the stacked cell 2904. As discussed herein, the separator layer 500 is adapted to electrically isolate the anodically active material layer 508 from the cathodically active material layer 512 while permitting an exchange of carrier ions therebetween.
In embodiments, the expansion gaps 3002 (and 3002a,b) as described above are used to provide room for the active materials within the stacked cell 2904 to expand. Upon charge and discharge cycling of a battery 1804 having the stacked cell 2904 carrier ions travel between the electrode (508, 512) and counter-electrode structures (508,512) and can intercalate into the anodically or cathodically active electrode material that is located within the direction of travel. The effect of intercalation and/or alloying of carrier ions into the electrode material can cause the material to swell or expand. Accordingly, the void space provided by the expansion gap 3002 allows the material to expand therein, without causing structural damage to the battery 1804. In some instances, if insufficient void space is provided by expansion gap 3002, or if spacer members 2700a-d are not used, and thus no expansion gap is provided, the battery 1804 may swell to a point where an outer casing thereof ruptures, or internal short-circuits occur. Accordingly, a suitable expansion gap 3002 should be provided using spacer members 2700a-d, as required depending on the desired performance of the battery 1804 and materials used. In some embodiments, the void fraction in expansion gap volume to active material volume may be less than 55%, such as less than 50%, less than 45%, less than 40%, and/or even less than 35%. In another embodiment, the void fraction may be greater than 90%, such as greater than 95%, greater than 98%, and/or even greater than 99%.
In one embodiment, the spacer members 2700a-d can comprise an electrically conductive material so as to maintain electrical connection between the electrode current collector layer and counter-electrode active material layer. The spacer members 2700a-d disposed between the electrode current collector layer and counter-electrode active material layer may also comprise protrusions, a surface roughness, or other features that impart the intended expansion gap and/or void fraction. In other embodiments, the spacer members 270a-d may comprise a material that is one or more of ionically, electrically, and electrochemically compatible (e.g., does not corrode) with adjacent structures (electrode structures, counter electrode structures, separators, battery casing materials, etc.), or with electrolyte and/or carrier ions in the battery 1804 or stacked cell 2904. Furthermore, in a case where the structures (e.g., electrode active materials, counter-electrode current collectors, electrode active materials, counter-electrode current collectors, separators) are themselves provided with protrusions and/or other features (e.g. surface roughness) that serve a spacer function to effect an expansion gap and/or increased void fraction in a certain region, the protrusions and/or other features may be similarly compatible with adjacent structures, electrolyte and/or carrier ions in the battery.
In some embodiments, the expansion gap 3002 or calculated void fraction may be provided over a plurality of electrode sub-units 2900a-d. For example, in one embodiment, the expansion gap 3002 or void fraction in a single electrode sub-unit 2900a-d may be less than the overall intended expansion gap or void fraction for the entire battery 1804 or stacked cell 2904, but other ones of the electrode sub-units 2900a-d may comprise larger expansion gaps 3002 or void fractions to accommodate the smaller expansion gaps 3002 or void fractions in other ones of the electrode sub-units 2900a-d. For example, in one embodiment, every other electrode sub-unit 2900a-d in a population may comprise an expansion gap 3002 and/or void fraction that is 2× to accommodate other ones of the electrode sub-units 2900a-d having substantially no gap and/or void fraction, or a smaller expansion gap or void fraction, where a cumulative gap over the population of electrode sub-units is intended to be N times x (where N is the number of individual electrode sub-units in the population). In another embodiment, every 5th electrode sub-unit in a population may comprise an expansion gap and/or void fraction that is 5× to accommodate other unit cells having substantially no expansion gap and/or void fraction, where a cumulative gap over the population of unit cells is intended to be N times x (where N is the number of electrode sub-units in the population). In yet another embodiment, every 10th electrode sub unit in a population may comprise an expansion gap and/or void fraction that is 10× to accommodate other electrode sub-units having substantially no expansion gap and/or void fraction, where a cumulative gap over the population of electrode sub units is intended to be N times x (where N is the number of unit cells in the population). In yet a further embodiment, for a cumulative gap over the population of electrode sub units that is intended to be N times x (where N is the number of electrode sub units in the population), the expansion gap and/or void fraction in an electrode sub unit in the population may be at least 1%, at least 5%, at least 10%, and/or at least 15% of the average gap and/or void space intended for the population (e.g., (N times x)/(number of unit cells in the population)), and may be less than 90%, less than 80%, less than 75%, less than 50%, less than 35%, less than 20%, less than 10%, and/or less than 5% of the average expansion gap and/or void space intended for the population (e.g., (N times x)/(number of electrode sub-units in the population)). The number of unit cells N in the population may be, for example, at least 2, 5, 8, 10, 15, 20, 30,40, 50, 75, 80, 80, 100, 150, 200, 300, 500, 800, 1000, or even greater, and/or the number N of electrode sub-units may correspond to the entire number of electrode sub-units in the battery 1804.
In some embodiments, the spacer members 2700a-d of one or more electrode sub-units may be removed prior to stacking a population of electrode sub-units into a stacked cell 2904. For example, in some embodiments, the spacer members 2700a-d may be provided in a margin that is defined distally (in the X-Axis Direction) of a base material layer such that the spacer members are outside (distal to) in the cross-web directions XWD one or more of the perforations 608, 610 such that when the perforations are ruptured during the punching and stacking operations described herein, that the spacer members 2700a-d are removed and do not become part of the stacked cell 2904. In such embodiments, the expansion gaps 3002 formed by the spacer members 2700a-d still remain even after the spacer members 2700a-d are removed from the electrode sub-units.
With reference to
As shown in
In some embodiments, with reference to
The following embodiments are provided to illustrate aspects of the disclosure, although the embodiments are not intended to be limiting and other aspects and/or embodiments may also be provided.
Embodiment 1. A secondary battery for cycling between a charged state and a discharged state, the battery comprises an enclosure and an electrode assembly disposed within the enclosure, wherein the electrode assembly has mutually perpendicular transverse, longitudinal, and vertical axes corresponding to the x, y and z axes, respectively, of a three-dimensional Cartesian coordinate system, the electrode assembly comprises a population of unit cells, each unit cell comprising an electrode current collector layer, an electrode layer, a separator layer, a counter-electrode layer, and a counter-electrode current collector layer in stacked succession in the longitudinal direction, the electrode layer comprises an electrode active material, and the counter-electrode layer comprises a counter-electrode active material, wherein one of the electrode active material and the counter-electrode material is a cathodically active material and the other of the electrode active material and the counter-electrode material is an anodically active material, a subset of the unit cell population further comprising a pair of spacer members located in the stacked succession between the electrode current collector layer and the counter-electrode current collector layer, one of the spacer members being spaced in the transverse direction from the other spacer member, at least a portion of the counter-electrode active material of the counter-electrode layer being located between the spacer members such that the portion of the counter-electrode active material and the spacer members lie in a common plane defined by the x and z axes.
Embodiment 1A. An electrode assembly having mutually perpendicular transverse, longitudinal, and vertical axes corresponding to the x, y and z axes, respectively, of a three-dimensional Cartesian coordinate system. The electrode assembly comprises a population of unit cells, each unit cell comprises an electrode current collector layer, an electrode layer, a separator layer, a counter-electrode layer, and a counter-electrode current collector layer in stacked succession in the longitudinal direction. The electrode layer comprises an electrode active material, and the counter-electrode layer comprises a counter-electrode active material. One of the electrode active material and the counter-electrode material is a cathodically active material and the other of the electrode active material and the counter-electrode material is an anodically active material. A subset of the unit cell population further comprises a pair of spacer members located in the stacked succession between the electrode current collector layer and the counter-electrode current collector layer. One of the spacer members is spaced in the transverse direction from the other spacer member. At least a portion of the counter-electrode active material of the counter-electrode layer is located between the spacer members such that the portion of the counter-electrode active material and the spacer members lie in a common plane defined by the x and z axes.
Embodiment 1B. An electrode assembly for cycling between a charged state and a discharged state in a battery, the battery comprising an enclosure and an electrode assembly disposed within the enclosure, wherein the electrode assembly has mutually perpendicular transverse, longitudinal, and vertical axes corresponding to the x, y and z axes, respectively, of a three-dimensional Cartesian coordinate system. The electrode assembly comprises a population of unit cells, each unit cell having a main body, a first edge margin, a second edge margin separated in the transverse direction from the first edge margin, a front, a back separated in the longitudinal direction from the front, a top, and a bottom separated in the vertical direction from the top, each main body comprising an electrode current collector layer, an electrode layer, a separator layer, a counter-electrode layer, and a counter-electrode current collector layer in stacked succession in the longitudinal direction. The electrode layer comprises an electrode active material, and the counter-electrode layer comprises a counter-electrode active material, wherein one of the electrode active material and the counter-electrode material is a cathodically active material and the other of the electrode active material and the counter-electrode material is an anodically active material. Each of the first edge margin and the second edge margin comprises (i) the electrode current collector layer, the separator layer, and the counter-electrode current collector layer, and (ii) a tape spacer, each of the tape spacers being adhered to at least one of (i) the electrode current collector, (ii) the electrode layer, (iii) the separator, and (iv) the counter-electrode current collector, the counter-electrode layer having a first end and a second end spaced in the transverse direction from the first end to define a transverse extent of the counter-electrode layer, the transverse extent of the counter-electrode layer terminating prior to the first edge margin and second edge margin.
Embodiment 1C. An electrode assembly for a battery configured to cycle between a charged state and a discharged state, the electrode assembly having mutually perpendicular transverse, longitudinal, and vertical axes corresponding to the x, y and z axes, respectively, of a three-dimensional Cartesian coordinate system, the electrode assembly having a main body, a first edge margin, a second edge margin separated in the transverse direction from the first edge margin, a front, a back separated in the longitudinal direction from the front, a top, and a bottom in the vertical direction from the top, the main body comprising an electrode current collector layer, an electrode layer, a separator layer, a counter-electrode layer, counter-electrode layer, and a counter-electrode current collector layer in stacked succession in the longitudinal direction. The electrode layer comprises an electrode active material, and the counter-electrode layer comprises a counter-electrode active material, wherein one of the electrode active material and the counter-electrode material is a cathodically active material and the other of the electrode active material and the counter-electrode material is an anodically active material. Each of the first edge margin and the second edge margins of the main body comprises (i) the electrode current collector layer, the separator layer, and the counter-electrode current collector layer, and (ii) a first tape spacer disposed in the first edge margin and a second tape spacer disposed in the second edge margin; each of the first tape spacer and the second tape spacer being adhered to at least one of (i) the electrode current collector, (ii) the electrode layer, (iii) the separator, and (iv) the counter-electrode current collector, the counter-electrode layer having a first end and a second end spaced in the transverse direction from the first end to define a transverse extent of the counter-electrode layer, the transverse extent of the counter-electrode layer terminating prior to the first edge margin and second edge margin.
Embodiment 1D. A secondary battery for cycling between a charged state and a discharged state, the battery comprising an enclosure and an electrode assembly disposed within the enclosure, wherein: the electrode assembly has mutually perpendicular transverse, longitudinal, and vertical axes corresponding to the x, y and z axes, respectively, of a three-dimensional Cartesian coordinate system, the electrode assembly comprises a population of unit cells, each unit cell comprising an electrode current collector layer, an electrode layer, a separator layer, a counter-electrode layer, and a counter-electrode current collector layer in stacked succession in the longitudinal direction, the electrode layer comprises an electrode active material, and the counter-electrode layer comprises a counter-electrode active material, wherein one of the electrode active material and the counter-electrode material is a cathodically active material and the other of the electrode active material and the counter-electrode material is an anodically active material, a subset of the unit cell population further comprising a pair of spacer members located in the stacked succession between the electrode current collector layer and the counter-electrode current collector layer, one of the spacer members being spaced in the transverse direction from the other spacer member of the pair of spacer members, at least a portion of the counter-electrode active material of the counter-electrode layer being located between the pair of spacer members such that the portion of the counter-electrode active material and the spacer members lie in a common plane defined by the x and z axes.
Embodiment 2. The secondary battery or electrode assembly set forth in any of Embodiments 1-1C wherein the counter-electrode layer has a central portion and a pair of flank portions on opposite sides of the central portion, the flank portions having a width equal to or less than 50 percent of a width of the central portion.
Embodiment 3. The secondary battery or electrode assembly set forth in any prior Embodiment wherein the width of the flank portions is less than 40 percent the width of the central portion.
Embodiment 4. The secondary battery or electrode assembly set forth in any prior Embodiment wherein the width of the flank portions is less than 30 percent the width of the central portion.
Embodiment 5. The secondary battery or electrode assembly set forth in any prior Embodiment wherein the width of the flank portions is less than 20 percent the width of the central portion.
Embodiment 6. The secondary battery or electrode assembly set forth in any prior Embodiment wherein the width of the flank portions is less than 10 percent the width of the central portion.
Embodiment 7. The secondary battery or electrode assembly set forth in any prior Embodiment wherein the counter-electrode layer has a maximum width measured between an interface with the counter-electrode current collector layer and an interface with the separator layer, the common plane occurring over at least 50 percent of the maximum width.
Embodiment 8. The secondary battery or electrode assembly set forth in any prior Embodiment wherein the common plane occurs over at least 60 percent of the maximum width.
Embodiment 9. The secondary battery or electrode assembly set forth in any prior Embodiment wherein the common plane occurs over at least 70 percent of the maximum width.
Embodiment 10. The secondary battery or electrode assembly set forth in any prior Embodiment wherein the common plane occurs over at least 80 percent of the maximum width.
Embodiment 11. The secondary battery or electrode assembly set forth in claim 10 wherein the common plane occurs over at least 90 percent of the maximum width.
Embodiment 12. The secondary battery or electrode assembly set forth in any prior Embodiment wherein the spacer members have a length extending in the transverse direction, the length of the spacer members being equal to or less than 500 μm.
Embodiment 13. The secondary battery or electrode assembly set forth in any prior Embodiment wherein the length of the spacer members is less than 400 μm.
Embodiment 14. The secondary battery or electrode assembly set forth in any prior Embodiment wherein the length of the spacer members is less than 300 μm.
Embodiment 15. The secondary battery or electrode assembly set forth in any prior Embodiment wherein the length of the spacer members is less than 200 μm.
Embodiment 16. The secondary battery or electrode assembly set forth in any prior Embodiment wherein the length of the spacer members is less than 100 μm.
Embodiment 17. The secondary battery or electrode assembly set forth in any prior Embodiment wherein the counter-electrode layer has a first end and a second end spaced in the transverse direction from the first end, the first end of the counter-electrode layer being adjacent to one of the spacer members and the second end of the counter-electrode layer being adjacent to the other one of the spacer members.
Embodiment 18. The secondary battery or electrode assembly set forth in any prior Embodiment wherein the first end and the second end correspond to the pair of flank portions.
Embodiment 19. The secondary battery or electrode assembly set forth in any prior Embodiment wherein the counter-electrode material is a cathodically active material, and the electrode active material is an anodically active material.
Embodiment 20. The secondary battery or electrode assembly set forth in any prior Embodiment wherein the electrode material is a cathodically active material, and the counter-electrode active material is an anodically active material.
Embodiment 21. The secondary battery or electrode assembly set forth in any prior Embodiment wherein the spacer members are disposed between the separator layer and the electrode layer.
Embodiment 22. The secondary battery or electrode assembly set forth in any prior Embodiment wherein the spacer members are disposed between the separator layer and the electrode current collector layer.
Embodiment 23. The secondary battery or electrode assembly set forth in any prior Embodiment wherein the spacer members are disposed between the separator and the counter-electrode layer.
Embodiment 24. The secondary battery or electrode assembly set forth in any prior Embodiment wherein the spacer members are disposed between the separator layer and the counter-electrode current collector layer.
Embodiment 25. The secondary battery or electrode assembly set forth in any prior Embodiment wherein the spacer members are adhered to at least one of the electrode current collector layer, the electrode layer, the separator layer, the counter-electrode layer, and the counter-electrode current collector layer.
Embodiment 26. The secondary battery or electrode assembly set forth in any prior Embodiment wherein the spacer members are adhered to the electrode current collector layer.
Embodiment 27. The secondary battery or electrode assembly set forth in any prior Embodiment wherein the spacer members are adhered to the electrode layer.
Embodiment 28. The secondary battery or electrode assembly set forth in any prior Embodiment wherein the spacer members are adhered to the separator layer.
Embodiment 29. The secondary battery or electrode assembly set forth in any prior Embodiment wherein the spacer members are adhered to the counter-electrode current collector layer.
Embodiment 30. The secondary battery or electrode assembly set forth in any prior Embodiment wherein the electrode layer has a first end and a second end spaced in the transverse direction from the first end to define a transverse extent of the electrode layer, the transverse extent of the electrode layer terminating prior to a terminus of the unit cell.
Embodiment 31. The secondary battery or electrode assembly set forth in any prior Embodiment wherein (i) the members of the unit cell population are in stacked succession in the longitudinal direction, (ii) the unit cell population comprises two sets of adjacent pairs of unit cells (iii) one of the two sets of the adjacent pairs share a common electrode current collector layer and the other of the two sets of the adjacent pairs share a common counter-electrode current collector layer.
Embodiment 32. The secondary battery or electrode assembly set forth in any prior Embodiment wherein the unit cell population comprises at least 5 members.
Embodiment 33. The secondary battery or electrode assembly set forth in any prior Embodiment wherein the unit cell population comprises at least 10 members.
Embodiment 34. The secondary battery or electrode assembly set forth in any prior Embodiment the unit cell population comprises at least 25 members.
Embodiment 35. The secondary battery or electrode assembly set forth in any prior Embodiment wherein the unit cell population comprises at least 50 members.
Embodiment 36. The secondary battery or electrode assembly set forth in any prior Embodiment wherein the unit cell population comprises at least 100 members.
Embodiment 37. The secondary battery or electrode assembly set forth in any prior Embodiment wherein the unit cell population comprises at least 250 members.
Embodiment 38. The secondary battery or electrode assembly set forth in any prior Embodiment wherein the unit cell population comprises at least 500 members.
Embodiment 39. The secondary battery or electrode assembly set forth in any prior Embodiment wherein the spacer members comprise an electrically insulating material.
Embodiment 40. The secondary battery or electrode assembly set forth in any prior Embodiment wherein the unit cell comprises a supplemental spacer.
Embodiment 41. The secondary battery or electrode assembly set forth in any prior Embodiment wherein the supplemental spacer comprises the same material as the separator layer.
Embodiment 42. The secondary battery or electrode assembly set forth in any prior Embodiment wherein the unit cell comprises a supplemental spacer comprising stabilized lithium metal particles.
Embodiment 43. The secondary battery or electrode assembly set forth in any prior Embodiment wherein the unit cell comprises a supplemental spacer comprising stabilized lithium metal particles selected from the group consisting of lithium carbonate-stabilized lithium metal powder, lithium silicate-stabilized lithium metal powder.
Embodiment 44. The secondary battery or electrode assembly set forth in any prior Embodiment wherein the unit cell comprises a supplemental spacer comprising the stabilized lithium metal particles applied by spraying, loading or otherwise disposing the stabilized lithium metal particles at a loading amount of about to 5 mg/cm2.
Embodiment 45. The secondary battery or electrode assembly set forth in any prior Embodiment wherein the unit cell comprises a supplemental spacer comprising the stabilized lithium metal particles applied by spraying, loading or otherwise disposing the stabilized lithium metal particles at a loading amount of about to 4 mg/cm2.
Embodiment 46. The secondary battery or electrode assembly set forth in any prior Embodiment wherein the unit cell comprises a supplemental spacer comprising the stabilized lithium metal particles applied by spraying, loading or otherwise disposing the stabilized lithium metal particles at a loading amount of about 0.5 to 3 mg/cm2.
Embodiment 47. The secondary battery or electrode assembly set forth in any prior Embodiment wherein the unit cell comprises a supplemental spacer comprising stabilized lithium metal particles having an average particle size (D50) of about 5 to 200 μm.
Embodiment 48. The secondary battery or electrode assembly set forth in any prior Embodiment wherein the unit cell comprises a supplemental spacer comprising stabilized lithium metal particles having an average particle size (D50) of about 10 to 100 μm.
Embodiment 49. The secondary battery or electrode assembly set forth in any prior Embodiment wherein the unit cell comprises a supplemental spacer comprising stabilized lithium metal particles having an average particle size (D50) of about 20 to 80 μm.
Embodiment 50. The secondary battery or electrode assembly set forth in any prior Embodiment wherein the unit cell comprises a supplemental spacer comprising stabilized lithium metal particles having an average particle size (D50) of about 30 to 50 μm.
Embodiment 51. The secondary battery or electrode assembly set forth in any prior Embodiment wherein the spacer members comprise a spacer material selected from the group consisting of polymeric materials, composites, a material comprised by the electrode current collector, an electrode active material, the counter-electrode active material, a material comprised by the counter-electrode current collector, a material comprised by the separator, or a material that is chemically inert in the battery environment.
Embodiment 52. The secondary battery or electrode assembly set forth in any prior Embodiment wherein the spacer members comprise an anodically active material.
Embodiment 53. The secondary battery or electrode assembly set forth in any prior Embodiment wherein the spacer members comprise an anodically active material having a capacity for carrier ions that is less than one mole of carrier ion per mole of spacer material.
Embodiment 54. The secondary battery or electrode assembly set forth in any prior Embodiment wherein the spacer members comprise graphite or graphene.
Embodiment 55. The secondary battery or electrode assembly set forth in any prior Embodiment wherein the spacer members comprise a cathodically active material.
Embodiment 56. The secondary battery or electrode assembly set forth in any prior Embodiment wherein the spacer members comprise a polymeric material.
Embodiment 57. The secondary battery or electrode assembly set forth in any prior Embodiment wherein the spacer members comprise a homopolymer, copolymer or polymer blend).
Embodiment 58. The secondary battery or electrode assembly set forth in any prior Embodiment wherein the spacer members comprise a fluoropolymer derived from monomers containing vinylidene fluoride, hexafluoropropylene, tetrafluoropropene, a polyolefin such as polyethylene, polypropylene, or polybutene, ethylene-diene-propene terpolymer, polystyrene, polymethyl methacrylate, polyethylene glycol, polyvinyl acetate, polyvinyl butyral, polyacetal, and polyethyleneglycol diacrylate, methyl cellulose, carboxymethyl cellulose, styrene rubber, butadiene rubber, styrene-butadiene rubber, isoprene rubber, polyacrylamide, polyvinyl ether, polyacrylic acid, polymethacrylic acid, polyacrylonitrile, polyvinylidene fluoride polyacrylonitrile, polyethylene oxide, acrylates, styrenes, epoxies, silicones, polyvinylidene fluoride-co-hexafluoropropylene, polyvinylidene fluoride-co-trichloroethylene, polymethylmethacrylate, polyacrylonitrile, polyvinylpyrrolidone, polyvinyl acetate, polyethylene-co-vinyl acetate, polyethylene oxide, cellulose acetate, cellulose acetate butyrate, cellulose acetate propionate, cyanoethylpullulan, cyanoethyl polyvinylalcohol, cyanoethylcellulose, cyanoethylsucrose, pullulan, carboxymetyl cellulose, acrylonitrile-styrene-butadiene copolymer, polyimide, polyvinylidene fluoride-hexafluoro propylene, polyvinylidene fluoride-trichloroethylene, polymethyl methacrylate, polyacrylonitrile, polyvinyl pyrrolidone, polyvinyl acetate, ethylene vinyl acetate copolymer, polyethylene oxide, cellulose acetate, cellulose acetate butyrate, cellulose acetate propionate, cyanoethyl pullulan, cyanoethyl polyvinyl alcohol, cyanoethyl cellulose, cyanoethyl sucrose, pullulan, carboxyl methyl cellulose, acrylonitrile styrene butadiene copolymer, polyimide, polyethylene terephthalate, polybutylene terephthalate, polyester, polyacetal, polyamide, polyetheretherketone, polyether sulfone, polyphenylene oxide, polyphenylene sulfide, polyethylene naphthalene, and/or combinations or a copolymer thereof.
Embodiment 59. The secondary battery or electrode assembly set forth in any prior Embodiment wherein the spacer members comprise a fluoropolymer.
Embodiment 60. The secondary battery or electrode assembly set forth in any prior Embodiment wherein the spacer members comprise a polyolefin.
Embodiment 61. The secondary battery or electrode assembly set forth in any prior Embodiment wherein the spacer members comprise a polyolefin selected from the group consisting of homopolymers, copolymers and polymer blends of polyethylene, polypropylene, and polybutene.
Embodiment 62. The secondary battery or electrode assembly set forth in any prior Embodiment wherein the spacer members comprise polyethylene or polypropylene.
Embodiment 63. The secondary battery or electrode assembly set forth in any prior Embodiment wherein the spacer members comprise an adhesive tape having a base and an adhesive layer provided on one surface of the base.
Embodiment 64. The secondary battery or electrode assembly set forth in any prior Embodiment wherein the spacer members comprise an adhesive tape having a base and an adhesive layer provided on one surface of the base wherein the adhesive tape base comprises a polymeric film selected from the group consisting of polyethylene, polypropylene, polyethylene terephthalate, polybutylene terephthalate, polyphenylene sulfide, polyimide, and polyamide films, and combinations, thereof.
Embodiment 65. The secondary battery or electrode assembly set forth in any prior Embodiment wherein the spacer members comprise an adhesive tape having a base and an adhesive layer provided on one surface of the base wherein the adhesive tape base comprises a polymeric film selected from the group consisting of polyolefin, polyethylene terephthalate and polyimide films.
Embodiment 66. The secondary battery or electrode assembly set forth in any prior Embodiment wherein the spacer members comprise an adhesive tape having a base and an adhesive layer provided on one surface of the base wherein the adhesive tape base has a thickness in the range of about 4 to 200 μm.
Embodiment 67. The secondary battery or electrode assembly set forth in any prior Embodiment wherein the spacer members comprise an adhesive tape having a base and an adhesive layer provided on one surface of the base wherein the adhesive tape base has a thickness in the range of about 6 to 150 μm.
Embodiment 68. The secondary battery or electrode assembly set forth in any prior Embodiment wherein the spacer members comprise an adhesive tape having a base and an adhesive layer provided on one surface of the base wherein the adhesive tape base has a thickness in the range of about 25 to 100 μm.
Embodiment 69. The secondary battery or electrode assembly set forth in any prior Embodiment wherein the spacer members comprise an adhesive tape having a base and an adhesive layer provided on one surface of the base wherein the adhesive constituting the adhesive layer of the adhesive tape comprises a rubber-based adhesive, an acrylic adhesive, a silicone-based adhesive or a combination thereof.
Embodiment 70. The secondary battery or electrode assembly set forth in any prior Embodiment wherein the spacer members comprise the same material as the separator layer.
Embodiment 71. The secondary battery or electrode assembly set forth in any prior Embodiment wherein the spacer members comprise an electrically conductive material.
Embodiment 72. The secondary battery or electrode assembly set forth in any prior Embodiment wherein the spacer members comprise the same material as the electrode layer.
Embodiment 73. The secondary battery or electrode assembly set forth in any prior Embodiment wherein the spacer members define, in part, transverse terminus of the unit cell.
Embodiment 74. The secondary battery or electrode assembly set forth in any prior Embodiment wherein the spacer members accommodate expansion of at least one of the electrode layer and the counter-electrode layer in the longitudinal direction while the battery is cycling between the charged state and the discharged state.
Embodiment 75. The secondary battery or electrode assembly set forth in any prior Embodiment wherein the spacer members accommodate expansion of the electrode layer.
Embodiment 76. The secondary battery or electrode assembly set forth in any prior Embodiment wherein a first portion of the separator layer lies in a first plane defined by the x and z axes, and a pair of second portions of the separator layer lies in a second plane defined by the x and z axes, the second plane being offset from the first plane in the longitudinal direction.
Embodiment 77. The secondary battery or electrode assembly set forth in any prior Embodiment wherein the first portion of the separator layer is disposed in face-to-face engagement with the counter-electrode layer, and the second portions of the separator layer is disposed adjacent a first end and a second end of the counter-electrode layer.
Embodiment 78. The secondary battery or electrode assembly set forth in any prior Embodiment wherein the electrode layer has a transverse extent and the counter-electrode layer has a transverse extent, the transverse extent of the electrode layer being greater than the transverse extend of the counter-electrode layer.
Embodiment 79. The secondary battery or electrode assembly set forth in any prior Embodiment wherein the transverse extent of the electrode layer is less than 500 nm greater than the transverse extend of the counter-electrode layer.
Embodiment 80. The secondary battery or electrode assembly set forth in any prior Embodiment wherein the transverse extent of the electrode layer is less than 400 μm greater than the transverse extend of the counter-electrode layer.
Embodiment 81. The secondary battery or electrode assembly set forth in any prior Embodiment wherein the transverse extent of the electrode layer is less than 300 μm greater than the transverse extend of the counter-electrode layer.
Embodiment 82. The secondary battery or electrode assembly set forth in any prior Embodiment wherein the transverse extent of the electrode layer is less than 200 μm greater than the transverse extend of the counter-electrode layer.
Embodiment 83. The secondary battery or electrode assembly set forth in claim 82 wherein the transverse extent of the electrode layer is less than 100 μm greater than the transverse extend of the counter-electrode layer.
Embodiment 84. The secondary battery or electrode assembly set forth in any prior Embodiment wherein the electrode layer has a transverse extent and the counter-electrode layer has a transverse extent, the transverse extent of the electrode layer being equal to the transverse extend of the counter-electrode layer.
Embodiment 85. The secondary battery or electrode assembly set forth in any prior Embodiment wherein the unit cell has a height measured in the vertical direction and the spacer members have a height measured in the vertical direction, the height of the unit cell being equal to the height of the spacer members.
Embodiment 86. The secondary battery or electrode assembly set forth in any prior Embodiment wherein the unit cell has a height measured in the vertical direction and the spacer members have a height measured in the vertical direction, the height of the unit cell being greater than the height of the spacer members.
Embodiment 87. The secondary battery or electrode assembly set forth in any prior Embodiment wherein the unit cell has a height measured in the vertical direction and the spacer members have a height measured in the vertical direction, the height of the unit cell being less than the height of the spacer members.
Embodiment 88. The secondary battery or electrode assembly set forth in any prior Embodiment wherein the pair of spacer members defines a first pair of spacer members and the subset of the unit cell population further comprises a second pair of spacer members located in the stacked succession between the electrode current collector layer and the counter-electrode current collector layer.
Embodiment 89. The secondary battery or electrode assembly set forth in any prior Embodiment wherein the spacer members of the first pair of spacer members are disposed on one side of the separator layer and the spacer members of the second pair of spacer members are disposed on the opposite side on the separator layer.
Embodiment 90. The secondary battery or electrode assembly set forth in any prior Embodiment wherein the spacer members of the first pair of spacer members are disposed between the separator layer and the counter-electrode current collector layer, and the spacer members of the second pair of spacer members are disposed between the separator layer and the electrode current collector layer.
Embodiment 91. The secondary battery or electrode assembly set forth in any prior Embodiment wherein one of the electrode active material and the counter-electrode material is an anodically active material selected from the group consisting of: (a) silicon (Si), germanium (Ge), tin (Sn), lead (Pb), antimony (Sb), bismuth (Bi), zinc (Zn), aluminum (Al), titanium (Ti), nickel (Ni), cobalt (Co), and cadmium (Cd); (b) alloys or intermetallic compounds of Si, Ge, Sn, Pb, Sb, Bi, Zn, Al, Ti, Ni, Co, or Cd with other elements; (c) oxides, carbides, nitrides, sulfides, phosphides, selenides, and tellurides of Si, Ge, Sn, Pb, Sb, Bi, Zn, Al, Ti, Fe, Ni, Co, V, or Cd, and their mixtures, composites, or lithium-containing composites; (d) salts and hydroxides of Sn; (e) lithium titanate, lithium manganate, lithium aluminate, lithium-containing titanium oxide, lithium transition metal oxide, ZnCo2O4; (f) particles of graphite and carbon; (g) lithium metal; and (h) combinations thereof.
Embodiment 92. The secondary battery or electrode assembly set forth in any prior Embodiment wherein one of the electrode active material and the counter-electrode material is an anodically active material selected from the group consisting of silicon (Si), germanium (Ge), tin (Sn), lead (Pb), antimony (Sb), bismuth (Bi), zinc (Zn), aluminum (Al), titanium (Ti), nickel (Ni), cobalt (Co), and cadmium (Cd).
Embodiment 93. The secondary battery or electrode assembly set forth in any prior Embodiment wherein one of the electrode active material and the counter-electrode material is an anodically active material selected from the group consisting of alloys and intermetallic compounds of Si, Ge, Sn, Pb, Sb, Bi, Zn, Al, Ti, Ni, Co, or Cd with other elements.
Embodiment 94. The secondary battery or electrode assembly set forth in any prior Embodiment wherein one of the electrode active material and the counter-electrode material is an anodically active material selected from the group consisting of oxides, carbides, nitrides, sulfides, phosphides, selenides, and tellurides of Si, Ge, Sn, Pb, Sb, Bi, Zn, Al, Ti, Fe, Ni, Co, V, and Cd.
Embodiment 95. The secondary battery or electrode assembly set forth in any prior Embodiment wherein one of the electrode active material and the counter-electrode material is an anodically active material selected from the group consisting of oxides, carbides, nitrides, sulfides, phosphides, selenides, and tellurides of Si.
Embodiment 96. The secondary battery or electrode assembly set forth in any prior Embodiment wherein one of the electrode active material and the counter-electrode material is an anodically active material selected from the group consisting of silicon and the oxides and carbides of silicon.
Embodiment 97. The secondary battery or electrode assembly set forth in any prior Embodiment wherein one of the electrode active material and the counter-electrode material is anodically active material comprising lithium metal.
Embodiment 98. The secondary battery or electrode assembly set forth in any prior Embodiment wherein one of the electrode active material and the counter-electrode material is an anodically active material selected from the group consisting of graphite and carbon.
Embodiment 99. The secondary battery or electrode assembly set forth in any prior Embodiment wherein within the enclosure the secondary battery further comprises a non-aqueous, organic electrolyte.
Embodiment 100. The secondary battery or electrode assembly set forth in any prior Embodiment wherein within the enclosure the secondary battery further comprises a non-aqueous electrolyte comprising a mixture of a lithium salt and an organic solvent.
Embodiment 101. The secondary battery or electrode assembly set forth in any prior Embodiment wherein within the enclosure the secondary battery further comprises a polymer electrolyte.
Embodiment 102. The secondary battery or electrode assembly set forth in any prior Embodiment wherein within the enclosure the secondary battery further comprises a solid electrolyte.
Embodiment 103. The secondary battery or electrode assembly set forth in any prior Embodiment wherein within the enclosure the secondary battery further comprises a solid electrolyte selected from the group consisting of sulfide-based electrolytes.
Embodiment 104. The secondary battery or electrode assembly set forth in any prior Embodiment wherein within the enclosure the secondary battery further comprises a solid electrolyte selected from the group consisting of lithium tin phosphorus sulfide (Li10SnP2Si2), lithium phosphorus sulfide (β-Li3PS4) and lithium phosphorus sulfur chloride iodide (Li6PS5Cl0.9I0.1).
Embodiment 105. The secondary battery or electrode assembly set forth in any prior Embodiment wherein within the enclosure the secondary battery further comprises a polymer based electrolyte.
Embodiment 106. The secondary battery or electrode assembly set forth in any prior Embodiment wherein within the enclosure the secondary battery further comprises a polymer electrolyte selected from the group consisting of PEO-based polymer electrolyte, polymer-ceramic composite electrolyte (solid), polymer-ceramic composite electrolyte, and polymer-ceramic composite electrolyte.
107. The secondary battery or electrode assembly set forth in any prior Embodiment wherein within the enclosure the secondary battery further comprises a solid electrolyte selected from the group consisting of oxide based electrolytes.
Embodiment 108. The secondary battery or electrode assembly set forth in any prior Embodiment wherein within the enclosure the secondary battery further comprises a solid electrolyte selected from the group consisting of lithium lanthanum titanate (Li0.34La0.56TiO3), Al-doped lithium lanthanum zirconate (Li6.24La3Zr2Al0.24O11.98), Ta-doped lithium lanthanum zirconate (Li6.4La3Zr1.4Ta0.6O12) and lithium aluminum titanium phosphate (Li1.4Al0.4Ti1.6(PO4)3).
Embodiment 109. The secondary battery or electrode assembly set forth in any prior Embodiment wherein one of the electrode active material and the counter-electrode material is a cathodically active material selected from the group consisting of intercalation chemistry positive electrodes and conversion chemistry positive electrodes.
Embodiment 110. The secondary battery or electrode assembly set forth in any prior Embodiment wherein one of the electrode active material and the counter-electrode material is a cathodically active material comprising an intercalation chemistry positive electrode material.
Embodiment 111. The secondary battery or electrode assembly set forth in any prior Embodiment wherein one of the electrode active material and the counter-electrode material is a cathodically active material comprising a conversion chemistry positive electrode active material.
Embodiment 112. The secondary battery or electrode assembly set forth in any prior Embodiment wherein one of the electrode active material and the counter-electrode material is a cathodically active material selected from the group consisting of S (or Li2S in the lithiated state), LiF, Fe, Cu, Ni, FeF2, FeOdF3.2d, FeF3, CoF3, CoF2, CuF2, NiF2, where 0≤d≤0.5.
Embodiment 113. A method of manufacturing a unit cell for use with a secondary battery, the method comprises stacking an electrode current collector layer, an electrode layer, a separator layer, a counter-electrode layer, and a counter-electrode current collector layer in succession in the longitudinal direction, the electrode layer comprises an electrode active material, and the counter-electrode layer comprises a counter-electrode active material, wherein one of the electrode active material and the counter-electrode material is a cathodically active material and the other of the electrode active material and the counter-electrode material is an anodically active material, and placing a pair of spacer members in the stacked succession between the electrode current collector layer and the counter-electrode current collector layer, one of the spacer members being spaced in a transverse direction from the other spacer member, at least a portion of the counter-electrode active material of the counter-electrode layer being located between the spacer members such that the portion of the counter-electrode active material and the spacer members lie in a common plane defined by an x axis and a z axis.
Embodiment 113A. A method of manufacturing an electrode assembly for use with a secondary battery. The method comprises stacking an electrode current collector layer, an electrode layer, a separator layer, a counter-electrode layer, and a counter-electrode current collector layer in succession in the longitudinal direction. The electrode layer comprises an electrode active material, and the counter-electrode layer comprises a counter-electrode active material. One of the electrode active material and the counter-electrode material is a cathodically active material and the other of the electrode active material and the counter-electrode material is an anodically active material. The method includes placing a pair of spacer members in the stacked succession between the electrode current collector layer and the counter-electrode current collector layer. One of the spacer members is spaced in a transverse direction from the other spacer member. At least a portion of the counter-electrode active material of the counter-electrode layer is located between the spacer members such that the portion of the counter-electrode active material and the spacer members lie in a common plane defined by an x axis and a z axis.
Embodiment 113B. A method of preparing an electrode assembly for a battery configured to cycle between a charged state and a discharged state, the method comprising: stacking an electrode current collector layer, an electrode layer, a separator layer, a counter-electrode layer, and a counter-electrode current collector layer in stacked succession in the longitudinal direction; wherein the electrode layer comprises an electrode active material, and the counter-electrode layer comprises a counter-electrode active material, wherein one of the electrode active material and the counter-electrode material is a cathodically active material and the other of the electrode active material and the counter-electrode material is an anodically active material, adhering a tape spacer to at least one of the electrode current collector layer, the electrode layer, the separator layer, the counter-electrode layer, or the counter-electrode current collector layer within a first edge margin and a second edge margin such that the first edge margin and the second edge margin comprises (i) the electrode current collector layer, the separator layer, and the counter-electrode current collector layer, and (ii) the tape spacer, wherein the counter-electrode layer has a first end and a second end spaced in the transverse direction from the first end to define a transverse extent of the counter-electrode layer, and the counter-electrode layer is provided such that the transverse extent of the counter electrode layer terminates prior to the first edge margin and second edge margin.
Embodiment 113C. A method of manufacturing a secondary battery or electrode assembly as set forth in any of Embodiments 1-112, the method comprising the method of any of Embodiments 113, 113A and 113B.
Embodiment 113D. A method of manufacturing a unit cell for use with a secondary battery, the unit cell having mutually perpendicular transverse, longitudinal, and vertical axes corresponding to the x, y and z axes, respectively, of a three-dimensional Cartesian coordinate system the method comprising: stacking an electrode current collector layer, an electrode layer, a separator layer, a counter-electrode layer, and a counter-electrode current collector layer in succession in the longitudinal axis direction, the electrode layer comprises an electrode active material, and the counter-electrode layer comprises a counter-electrode active material, wherein one of the electrode active material and the counter-electrode material is a cathodically active material and the other of the electrode active material and the counter-electrode material is an anodically active material, and placing a pair of spacer members in the stacked succession between the electrode current collector layer and the counter-electrode current collector layer, one of the spacer members being spaced in a transverse direction from the other spacer member, at least a portion of the counter-electrode active material of the counter-electrode layer being located between the spacer members such that the portion of the counter-electrode active material and the spacer members lie in a common plane defined by the x axis and the z axis.
Embodiment 114. The method set forth in any of Embodiments 113-113C wherein the spacer members are placed between the separator layer and the electrode layer.
Embodiment 115. The method set forth in any prior Embodiment wherein the spacer members are placed between the separator layer and the electrode current collector layer.
Embodiment 116. The method set forth in any prior Embodiment wherein the spacer members placed between the separator and the counter-electrode layer.
Embodiment 117. The method set forth in any prior Embodiment wherein the spacer members are placed between the separator layer and the counter-electrode current collector layer.
Embodiment 118. The method set forth in any prior Embodiment wherein the spacer members are adhered to at least one of the electrode current collector layer, the electrode layer, the separator layer, the counter-electrode layer, and the counter-electrode current collector layer.
Embodiment 119. The method set forth in any prior Embodiment wherein the spacer members are adhered to the electrode current collector layer.
Embodiment 120. The method set forth in any prior Embodiment wherein the spacer members are adhered to the electrode layer.
Embodiment 121. The method set forth in any prior Embodiment wherein the spacer members are adhered to the separator layer.
Embodiment 122. The method set forth in any prior Embodiment wherein the spacer members are adhered to the counter-electrode current collector layer.
Embodiment 123. The method set forth in any prior Embodiment further comprising placing a supplemental spacer in the stacked succession between the electrode current collector layer and the counter-electrode current collector layer.
Embodiment 124. The method set forth in any prior Embodiment wherein a first portion of the separator layer is stacked in face-to-face engagement with the counter-electrode layer, and second portions of the separator layer are stacked adjacent a first end and a second end of the counter-electrode layer.
Embodiment 125. The method set forth in any prior Embodiment wherein the electrode current collector layer, the electrode layer, the separator layer, the counter-electrode layer, and the counter-electrode current collector layer are stacked on alignment pins.
Embodiment 126. The method set forth in any prior Embodiment wherein the pair of spacer members is placed on the alignment pins between the electrode current collector layer and the counter-electrode current collector layer.
Embodiment 127. A method for merging a plurality of webs of electrode materials, the process comprises: unwinding a first web of the electrode material along a first web merge path, the first web comprising a population of electrode sub-units delineated by corresponding weakened tear patterns and a population of first conveying features, unwinding a second web of the electrode material along a second web merge path downstream of the first web merge path, the second web comprising a population of electrode sub-units delineated by corresponding weakened tear patterns and a population of second conveying features; conveying a belt comprising a plurality of projections in a web merge direction adjacent the first web merge path and the second web merge path, the plurality of projections configured to engage with the first conveying features of the first web and the second conveying features of the second web; inserting a population of spacer members between the first web of electrode material and the second web of electrode material; and overlaying the second web of the electrode material on the first web of electrode material at a second web merge location downstream of the first web merge location, the population of spacer members being captured between the first web of electrode material and the second web of electrode material.
Embodiment 127A. A method for merging a plurality of webs of electrode materials, the process comprising: unwinding a first web of the electrode material along a first web merge path, the first web comprising a population of electrode sub-units delineated by corresponding weakened tear patterns and a population of first conveying features, unwinding a second web of the electrode material along a second web merge path downstream of the first web merge path, the second web comprising a population of electrode sub-units delineated by corresponding weakened tear patterns and a population of second conveying features; conveying a belt comprising a plurality of projections in a web merge direction adjacent the first web merge path and the second web merge path, the plurality of projections configured to engage with the first conveying features of the first web and the second conveying features of the second web; inserting a population of spacer members between the first web of electrode material and the second web of electrode material; and overlaying the second web of the electrode material on the first web of electrode material at a second web merge location downstream of the first web merge location, the population of spacer members being captured between the first web of electrode material and the second web of electrode material.
Embodiment 128. The method set forth in any prior Embodiment wherein inserting a population of spacer members between the first web of electrode material and the second web of electrode material comprises unwinding a web comprising a population of spacer members and merging the web of spacer members between the first web of electrode material and the second web of electrode material.
Embodiment 129. The method set forth in any prior Embodiment wherein inserting a population of spacer members between the first web of electrode material and the second web of electrode material comprises unwinding a web comprising a population of spacer members and unwinding a web comprising a plurality of separator members, and merging the web of spacer members adjacent to the web of separator members and between the first web of electrode material and the second web of electrode material.
This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.
This application claims priority to U.S. Provisional Patent Application 63/115,266, filed 18 Nov. 2020 and U.S. Provisional Application Ser. No. 63/115,578 filed 18 Nov. 2020. Both of these provisional applications are incorporated herein in their entireties by reference. Reference is made to U.S. patent application Ser. No. 16/533,082, filed on 6 Aug. 2019, which claims priority to U.S. Provisional Patent Application No. 62/715,233, filed 6 Aug. 2018, and to International Patent Application No. PCT/US2018/061245, filed 15 Nov. 2018, which claims priority to US Provisional Applications Nos. 62/586,737, filed 15 Nov. 2017 and 62/715,233, filed 6 Aug. 2018, each of these applications are hereby incorporated by reference in their entireties.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/US2021/059716 | 11/17/2021 | WO |
| Number | Date | Country | |
|---|---|---|---|
| 63115266 | Nov 2020 | US | |
| 63115578 | Nov 2020 | US |
