US 12,087,947 B2
Electrode assembly, secondary battery, and method of manufacture
Robert S. Busacca, San Francisco, CA (US); Ashok Lahiri, Cupertino, CA (US); Murali Ramasubramanian, Fremont, CA (US); Bruno A. Valdes, Sunnyvale, CA (US); Gardner Cameron Dales, Los Gatos, CA (US); Christopher J. Spindt, Menlo Park, CA (US); Geoffrey Matthew Ho, San Ramon, CA (US); Harrold J. Rust, III, Alamo, CA (US); James D. Wilcox, Pleasanton, CA (US); John F. Varni, Los Gatos, CA (US); Kim Han Lee, Pleasanton, CA (US); Nirav S. Shah, Pleasanton, CA (US); Richard J. Contreras, Campbell, CA (US); Lynn Van Erden, Pollock Pines, CA (US); Ken S. Matsubayashi, Fremont, CA (US); Jeremie J. Dalton, San Jose, CA (US); Jason Newton Howard, Alpharetta, GA (US); Robert Keith Rosen, Rocklin, CA (US); Jonathan C. Doan, Pleasanton, CA (US); Michael J. Armstrong, Danville, CA (US); Anthony Calcaterra, Milpitas (CA); Benjamin L. Cardozo, Palo Alto, CA (US); Joshua David Winans, Mountain View, CA (US); Neelam Singh, Fremont, CA (US); Jeffrey Glenn Buck, Salinas, CA (US); Thomas John Schuerlein, Pleasanton, CA (US); Kim Lester Fortunati, Pleasanton, CA (US); and Neal Sarswat, Pleasanton, CA (US)
Assigned to Enovix Corporation, Fremont, CA (US)
Filed by Enovix Corporation, Fremont, CA (US)
Filed on Sep. 10, 2021, as Appl. No. 17/471,499.
Application 17/471,499 is a continuation of application No. 16/763,078, granted, now 11,128,020, issued on Sep. 21, 2021, previously published as PCT/US2018/061245, filed on Nov. 15, 2018.
Claims priority of provisional application 62/715,233, filed on Aug. 6, 2018.
Claims priority of provisional application 62/586,737, filed on Nov. 15, 2017.
Prior Publication US 2022/0115753 A1, Apr. 14, 2022
This patent is subject to a terminal disclaimer.
Int. Cl. H01M 10/0525 (2010.01); H01M 4/134 (2010.01); H01M 4/38 (2006.01); H01M 4/48 (2010.01); H01M 4/525 (2010.01); H01M 4/66 (2006.01); H01M 10/04 (2006.01); H01M 10/054 (2010.01); H01M 10/0565 (2010.01); H01M 10/0585 (2010.01); H01M 50/103 (2021.01); H01M 50/46 (2021.01); H01M 50/54 (2021.01); H01M 4/02 (2006.01)
CPC H01M 4/525 (2013.01) [H01M 4/134 (2013.01); H01M 4/386 (2013.01); H01M 4/483 (2013.01); H01M 4/661 (2013.01); H01M 4/669 (2013.01); H01M 10/0436 (2013.01); H01M 10/0525 (2013.01); H01M 10/054 (2013.01); H01M 10/0565 (2013.01); H01M 10/0585 (2013.01); H01M 50/103 (2021.01); H01M 50/46 (2021.01); H01M 50/54 (2021.01); H01M 2004/027 (2013.01); H01M 2004/028 (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 and an electrode assembly, carrier ions, populations of first and second electrically insulating layers, and a set of electrode constraints, wherein:
(a) the electrode assembly has mutually perpendicular transverse, longitudinal and vertical axes corresponding to the x, y and z axes, respectively, of an imaginary three-dimensional cartesian coordinate system, a first longitudinal end surface and a second longitudinal end surface separated from each other in the longitudinal direction, and a lateral surface surrounding an electrode assembly longitudinal axis AEA and connecting the first and second longitudinal end surfaces, the lateral surface having opposing first and second regions on opposite sides of the longitudinal axis and separated in a first direction that is orthogonal to the longitudinal axis, the electrode assembly having a maximum width WEA measured in the longitudinal direction, a maximum length LEA bounded by the lateral surface and measured in the transverse direction, and a maximum height HEA bounded by the lateral surface and measured in the vertical direction,
(b) the electrode assembly further comprises a population of electrode structures, a population of electrode current collectors, a population of separators that are ionically permeable to carrier ions, a population of counter-electrode structures, a population of counter-electrode collectors, and a population of unit cells wherein
(i) members of the electrode and counter-electrode structure populations are arranged in an alternating sequence in the longitudinal direction,
(ii) each member of the population of electrode structures comprises a layer of an electrode active material having a length LE that corresponds to the Feret diameter of the electrode active material layer as measured in the transverse direction between first and second opposing transverse end surfaces of the electrode active material layer, and a height HE that corresponds to the Feret diameter of the electrode active material layer as measured in the vertical direction between first and second opposing vertical end surfaces of the electrode active material layer, and a width WE that corresponds to the Feret diameter of the electrode active material layer as measured in the longitudinal direction between first and second opposing surfaces of the electrode active material layer, and each member of the population of counter-electrode structures comprises a layer of a counter-electrode active material having a length LC that corresponds to the Feret diameter of the counter-electrode active material layer as measured in the transverse direction between first and second opposing transverse end surfaces of the counter-electrode active material layer, and a height HC that corresponds to the Feret diameter of the counter-electrode active material layer as measured in the vertical direction between first and second opposing vertical end surfaces of the counter-electrode active material layer, and a width WC that corresponds to the Feret diameter of the counter-electrode active material layer as measured in the longitudinal direction between first and second opposing surfaces of the counter-electrode active material layer
(iii) each unit cell comprises a unit cell portion of a first member of the electrode current collector of the electrode current collector population, a first electrode active material layer of one member of the electrode population, a member of the separator population that is ionically permeable to the carrier ions, a first counter-electrode active material layer of one member of the counter-electrode population, and a unit cell portion of a first member of the counter-electrode current collector of the counter-electrode current collector population, wherein (aa) the first electrode active material layer is proximate a first side of the separator and the first counter-electrode material layer is proximate an opposing second side of the separator, and (bb) the separator electrically isolates the first electrode active material layer from the first counter-electrode active material layer, and carrier ions are primarily exchanged between the first electrode active material layer and the first counter-electrode active material layer via the separator of each such unit cell during cycling of the battery between the charged and discharged state, (cc) within each unit cell,
a. the first vertical end surfaces of the electrode and the counter-electrode active material layers are on the same side of the electrode assembly, a 2D map of the median vertical position of the first opposing vertical end surface of the electrode active material in the X-Z plane, along the length LE of the electrode active material layer, traces a first vert¬¬ical end surface plot, EVP1, a 2D map of the median vertical position of the first opposing vertical end surface of the counter-electrode active material layer in the X-Z plane, along the length LC of the counter-electrode active material layer, traces a first vertical end surface plot, CEVP1, wherein for at least 60% of the length LC of the first counter-electrode active material layer (i) the absolute value of a separation distance, SZ1, between the plots EVP1 and CEVP1 measure¬d in the vertical direction is 1000 μm≥|SZ1|≥5 μm, and (ii) as between the first vertical end surfaces of the electrode and counter-electrode active material layers, the first vertical end surface of the counter-electrode active material layer is inwardly disposed with respect to the first vertical end surface of the electrode active material layer, and
b. the second vertical end surfaces of the electrode and counter-electrode active material layer are on the same side of the electrode assembly, and oppose the first vertical end surfaces of the electrode and counter-electrode active material layers, respectively, a 2D map of the median vertical position of the second opposing vertical end surface of the electrode active material layer in the X-Z plane, along the length LE of the electrode active material layer, traces a second vertical end surface plot, EVP2, a 2D map of the median vertical position of the second opposing vertical end surface of the counter-electrode active material layer in the X-Z plane, along the length LC of the counter-electrode active material layer, traces a second vertical end surface plot, CEVP2, wherein for at least 60% of the length LC of the counter-electrode active material layer (i) the absolute value of a separation distance, SZ2, between the plots EVP2 and CEVP2 as measured in the vertical direction is 1000 μm≥|SZ2|≥5 μm, and (ii) as between the second vertical end surfaces of the electrode and counter-electrode active material layers, the second vertical end surface of the counter-electrode active material layer is inwardly disposed with respect to the second vertical end surface of the electrode active material layer,
(c) the set of electrode constraints comprises (i) a primary constraint system comprising first and second primary growth constraints and at least one primary connecting member, the first and second primary growth constraints separated from each other in the longitudinal direction, and the at least one primary connecting member connecting the first and second primary growth constraints, wherein the primary constraint system restrains growth of the electrode assembly in the longitudinal direction, and (ii) a secondary constraint system comprising first and second secondary growth constraints separated in a second direction and connected by at least one secondary connecting member, wherein the secondary constraint system at least partially restrains growth of the electrode assembly in the second direction upon cycling of the secondary battery, the second direction being orthogonal to the longitudinal direction; and
(d) members of the population of first electrically insulating layers and members of the population of second electrically insulating layers are disposed at respective first and second vertical end surfaces of counter-electrode active material layers of members of the counter-electrode structure population, the members of the populations of first and second electrically insulating layers being disposed between the first and second vertical end surfaces of the counter-electrode active material layers and the respective first and second secondary growth constraints proximate each of the first and second vertical end surfaces in the vertical direction.