Granted Patent B2

US 12,327,833 · App. 18/531,197 · Granted Jun 10, 2025

Inventors: Robert S. Busacca (Francisco, CA); Ashok Lahiri (Cupertino, CA); Murali S. Ramasubramanian (Fremont, CA); Bruno A. Valdes (Sunnyvale, CA); Gardner Cameron Dales (Los Gatos, CA); Christopher J. Spindt (Menlo Park, CA); Geoffrey Matthew Ho (San Ramon, CA); Harrold J. Rust, III (Alamo, CA); James D. Wilcox (Pleasanton, CA); John F. Varni (Campbell, CA); Kim Han Lee (Pleasanton, CA); Nirav S. Shah (Pleasanton, CA); Richard J. Contreras (Campbell, CA); Lynn Van Erden (Pollock Pines, CA); Ken S. Matsubayashi (Fremont, CA); Jeremie J. Dalton (San Jose, CA)

Assignee: Enovix Corporation

H01M10/0468H01M10/0525H01M50/446H01M50/491H01M2004/021H01M50/414H01M50/417H01M50/426H01M50/497H01M50/55H01M50/553

Abstract

Claims (24)

1. A secondary battery for cycling between a charged state and a discharged state, the secondary battery comprising an enclosure that seals a contents of the secondary battery, an electrode assembly and a non-aqueous liquid electrolyte within the enclosure, and a constraint within the enclosure configured to maintain a pressure on the electrode assembly as the secondary battery is cycled between the charged state and the discharged state, the electrode assembly comprising a population of electrode structures, a population of counter-electrode structures and an electrically insulating separator material between each pair of electrode structure and counter electrode structure of members of the population of electrode structures and the population of counter-electrode structures, respectively,

the electrode assembly having opposing first and second longitudinal end surfaces separated along a longitudinal axis, and a lateral surface surrounding the longitudinal axis and connecting the first and second longitudinal end surfaces,

members of the population of electrode structures and members of the population of counter-electrode structures being arranged in an alternating sequence in a stacking direction that parallels the longitudinal axis within the electrode assembly,

the constraint comprising first and second compression members connected by at least one tension member configured to pull the first and second compression members toward each other, and

the constraint maintaining the pressure on the electrode assembly in the stacking direction such that the pressure exceeds a second pressure maintained on the electrode assembly in each of two directions that are mutually perpendicular to each other, and perpendicular to the stacking direction.

2. The secondary battery of claim 1 , wherein the electrically insulating separator material comprises an electrically insulating microporous separator material.

3. The secondary battery of claim 1 , wherein a combined surface area of the first and second longitudinal end surfaces is less than 33% of a combined surface area of the lateral surface and of the first and second longitudinal end surfaces.

4. The secondary battery of claim 1 , wherein a projection of the members of the population of electrode structures and the members of the population of counter-electrode structures onto the first longitudinal end surface circumscribes a first projected area and a projection of the members of the population of electrode structures and the members of the population of counter-electrode structures onto the second longitudinal end surface circumscribes a second projected area, and wherein the constraint imposes an average compressive force to each of the first and second projected areas of at least 0.7 kPa, averaged over a surface area of the first and second projected areas, respectively, the second longitudinal end surface and the first longitudinal end surface being of the first and second longitudinal end surfaces.

5. The secondary battery of claim 4 , wherein the average compressive force imposed by the constraint to each of the first and second projected areas is at least 2.8 kPa, averaged over the surface area of the first and second projected areas, respectively.

6. The secondary battery of claim 4 , wherein the average compressive force imposed by the constraint to each of the first and second projected areas is at least 5.25 kPa, averaged over the surface area of the first and second projected areas, respectively.

7. The secondary battery of claim 4 , wherein the average compressive force imposed by the constraint to each of the first and second projected areas is at least 8.75 kPa, averaged over the surface area of the first and second projected areas, respectively.

8. The secondary battery of claim 1 , wherein the constraint and the enclosure have a combined volume that is less than 60% of a volume enclosed by the enclosure.

9. The secondary battery of claim 1 , wherein the constraint and the enclosure have a combined volume that is less than 30% of a volume enclosed by the enclosure.

10. The secondary battery of claim 2 , wherein the electrically insulating microporous separator material comprises a particulate material and a binder, has a void fraction of at least 20 vol. %, and is permeated by the non-aqueous liquid electrolyte.

11. The secondary battery of claim 1 , wherein a distance between the at least one tension member and the lateral surface is less than 50% of a smallest of an Feret diameter of the electrode assembly, with the Feret diameter being measured in a direction of the distance between the at least one tension member and the lateral surface of the electrode assembly.

12. The secondary battery of claim 1 , wherein a distance between the at least one tension member and the lateral surface is less than 30% of a smallest of an Feret diameter of the electrode assembly, with the Feret diameter being measured in a direction of the distance between the at least one tension member and the lateral surface of the electrode assembly.

13. The secondary battery of claim 1 , wherein the electrode structures comprise an anodically active electroactive material and the counter-electrode structures comprise a cathodically active electroactive material.

14. The secondary battery of claim 1 , wherein the secondary battery comprises a set of at least two electrode assemblies and the constraint maintains an additional pressure on the electrode assemblies within the set of at least two electrode assemblies as the secondary battery is cycled between the charged state and the discharged state.

15. The secondary battery of claim 1 , wherein the electrode assembly comprises at least 5 electrode structures and at least 5 counter-electrode structures.

16. The secondary battery of claim 1 , wherein the constraint comprises a material having an ultimate tensile strength of at least 10,000 psi (>70 MPa).

17. The secondary battery of claim 1 , wherein the constraint comprises metal, metal alloy, ceramic, glass, plastic, or a combination thereof.

18. The secondary battery of claim 1 , wherein the constraint comprises a sheet of material having a thickness in a range of about 10 to about 100 micrometers.

19. The secondary battery of claim 1 , wherein the first and second compression members exert a third pressure on the first and second longitudinal end surfaces that exceeds the second pressure maintained on the electrode assembly in each of two directions that are mutually perpendicular and perpendicular to the stacking direction by a factor of at least 3.

20. The secondary battery of claim 1 , wherein the first and second compression members exert a third pressure on the first and second longitudinal end surfaces that exceeds the second pressure maintained on the electrode assembly in each of two directions that are mutually perpendicular and perpendicular to the stacking direction by a factor of at least 4.

Assignments (4)

Continuity (5)

References Cited (330)