US 12,255,353 B2
Electrode assembly, secondary battery, and method of manufacture
Jeremie J. Dalton, San Jose, CA (US); Robert S. Busacca, San Francisco, CA (US); Ashok Lahiri, Cupertino, CA (US); Murali Ramasubramanian, Fremont, CA (US); Bruno A. Valdes, Sunnyvale, CA (US); Kim Han Lee, Pleasanton, CA (US); Anthony Calcaterra, Milpitas, CA (US); and Benjamin L. Cardozo, Palo Alto, CA (US)
Assigned to Enovix Corporation, Fremont, CA (US)
Filed by Enovix Corporation, Fremont, CA (US)
Filed on Nov. 12, 2021, as Appl. No. 17/525,397.
Application 17/525,397 is a continuation of application No. PCT/US2020/033038, filed on May 15, 2020.
Claims priority of provisional application 62/849,071, filed on May 16, 2019.
Prior Publication US 2022/0069421 A1, Mar. 3, 2022
Int. Cl. H01M 50/474 (2021.01); H01M 10/0585 (2010.01); H01M 10/0587 (2010.01)
CPC H01M 50/474 (2021.01) [H01M 10/0585 (2013.01); H01M 10/0587 (2013.01)] 20 Claims
OG exemplary drawing
 
1. A secondary battery for cycling between a charged and a discharged state, the secondary battery comprising: a battery enclosure, an electrode assembly, carrier ions, a non-aqueous liquid electrolyte within the battery enclosure, wherein:
the electrode assembly comprises a population of unit cells, each unit cell of the population of unit cells comprising, in a stacked succession, (a) a first unit cell portion of an electrode current collector layer, (b) an electrode layer comprising electrode active material, the electrode active material comprising silicon, (c) a separator layer, (d) a counter-electrode layer, and (e) a second unit cell portion of a counter-electrode current collector layer, the unit cell having a width, Wuc, measured in a stacking direction of the stacked succession from the first unit cell portion of the electrode current collector to the second unit cell portion of the counter-electrode current collector, the electrode layer having a width, WE, measured in the stacking direction of the stacked succession from the first unit cell portion of the electrode current collector adjacent the electrode layer to the separator layer adjacent the electrode layer, a height, HE, measured from a top surface to a bottom surface of the electrode layer in a second direction orthogonal to the stacking direction, and a length, LE, measured from a first surface to a second surface in a third direction that is orthogonal to the stacking direction and the height direction, and a volume, VE, bounded by the first unit cell portion of the electrode current collector, the separator layer, the top surface of the electrode layer, the bottom surface of the electrode layer, the first end surface of the electrode layer, and the second end surface of the electrode layer, and
the electrode layer comprises a population of spacer structures comprising a material other than the electrode active material, the population of spacer structures being disposed at an interface between the electrode active material and the separator layer, and wherein the electrode layer comprises an electrode active material located between members of the population of spacer structures that are separated from each other in the third direction along the length LE of the electrode layer, wherein the population of spacer structures occupies a total volume within the electrode layer within the range of from about 0.1% to about 5% of the volume, VE, of the electrode layer.