IP Library › Granted Patent US 12,347,821
Granted Patent B2
US 12,347,821 · App. 18/599,952 · Granted Jul 1, 2025

Dimensional constraints for three-dimensional batteries

Inventors: Robert S. Busacca (Oakland, CA); Ashok Lahiri (Cupertino, CA); Murali 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); Vladimir Dioumaev (San Jose, CA)
Assignee: Enovix Corporation
H01M10/02H01M4/02H01M10/052H01M10/0525H01M10/054H01M10/058H01M10/0585H01M10/44H01M2004/021
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Quick Facts
Patent No.
US 12,347,821
App. No.
18/599,952
Granted
Jul 1, 2025
Kind
B2
Abstract

A secondary battery is provided for cycling between a charged and a discharged state, the secondary battery including a battery enclosure, an electrode assembly, carrier ions, a non-aqueous liquid electrolyte within the battery enclosure, and a set of electrode constraints. The set of electrode constraints includes a primary constraint system having first and second primary growth constraints and at least one primary connecting member, the first and second primary growth constraints separated from each other in the longitudinal direction, wherein the primary constraint array restrains growth of the electrode assembly in the longitudinal direction such that any increase in the Feret diameter of the electrode assembly in the longitudinal direction over 20 consecutive cycles of the secondary battery is less than 20%. The set of electrode constraints further includes a secondary constraint system having first and second secondary growth constraints connected by at least one secondary connecting member, wherein the secondary constraint system at least partially restrains growth of the electrode assembly in a second direction upon cycling of the secondary battery.

Claims (27)

1. A structure for cycling between a charged and a discharged state in a secondary battery, the structure comprising: an electrode assembly and a constraint,

the electrode assembly comprising (a) a population of electrode structures, (b) a population of counter-electrode structures, (c) an electrically insulating separator material between members of the population of electrode structures and the population of counter-electrode structures, (d) an electrode bus, and (e) a counter-electrode bus,

the electrode assembly having a shape that corresponds to a rectangular prism having (A) first and second longitudinal end surfaces opposing each other and separated along a longitudinal axis, and (B) a lateral surface surrounding the longitudinal axis and connecting the first and second longitudinal end surfaces with each other, a surface area of the first and second longitudinal end surfaces being less than 25% of a combined surface area of the lateral surface and of 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 and in a stacking direction parallel to the longitudinal axis within the electrode assembly,

each member of the population of electrode structures having a bottom, a top, a length (L E ), a width (W E ), a height (H E ), a perimeter (P E ), and a central longitudinal axis A E extending from the bottom to the top of each such member of the population of electrode structures and in a transverse direction that is generally perpendicular to the stacking direction, the L E of each member of the population of electrode structures being measured in the transverse direction, the width W E of each member of the population of electrode structures being measured in the stacking direction, the height H E of each member of the population of electrode structures being measured in a vertical direction perpendicular to each of the transverse direction and of the stacking direction, the P E of each member of the population of electrode structures being a sum of one or more lengths of one or more sides of each such member of the population of electrode structures in a plane that is normal to the central longitudinal axis A E , a ratio of the L E to the P E of each member of the population of electrode structures being at least 1.25:1,

a projection of the members of the population of electrode structures and 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 population of counter-electrode structures onto the second longitudinal end surface circumscribes a second projected area,

the constraint comprises first and second primary compression members that overlie the first and second projected areas, respectively, the first and second primary compression members being connected by first and second primary connecting members that overlie the lateral surface of the electrode assembly and pull the first and second primary compression members toward each other, and

the constraint is adapted to maintain a pressure on the electrode assembly in the stacking direction that exceeds an additional pressure maintained on the electrode assembly in each of the transverse direction and the vertical direction during cycling of the electrode assembly between the charged and the discharged state.

2. The structure according to claim 1 , wherein the electrode bus and the counter-electrode bus are separated from each other in the transverse direction, the electrode bus is electrically connected to, and pools current from, each member of the population of electrode structures, the counter-electrode bus is electrically connected to, and pools current from, each member of the population of counter-electrode structures, and the electrode bus and the counter-electrode bus extend in the stacking direction substantially an entire distance of the alternating sequence of the population of electrode structures and the population of counter-electrode structures.

3. The structure according to claim 1 , wherein the surface area of the first and second longitudinal end surfaces is less than 20% of the combined surface area of the lateral surface and the first and second longitudinal end surfaces.

4. The structure according to claim 1 , wherein the surface area of the first and second longitudinal end surfaces is less than 15% of the combined surface area of the lateral surface and the first and second longitudinal end surfaces.

5. The structure according to claim 1 , wherein the surface area of the first and second longitudinal end surfaces is less than 10% of the combined surface area of the lateral surface and the first and second longitudinal end surfaces.

6. The structure according to claim 1 , wherein the ratio of the L E to the P E of each member of the population of electrode structures being at least 2.5:1.

7. The structure according to claim 1 , wherein the ratio of the L E to the P E of each member of the population of electrode structures being at least 3.75:1.

8. The structure according to claim 1 , wherein the P E is within a range of from about 0.025 mm to about 25 mm.

9. The structure according to claim 1 , wherein the P E is within a range of from about 0.1 mm to about 15 mm.

10. The structure according to claim 1 , wherein the P E is within a range of from about 0.5 mm to about 10 mm.

11. The structure according to claim 1 , wherein the electrode assembly comprises at least ten (10) electrode structures and at least ten (10) counter-electrode structures.

12. The structure according to claim 1 , wherein the electrode assembly comprises at least 50 electrode structures and at least 50 counter-electrode structures.

13. The structure according to claim 1 , wherein the first and second primary connecting members are affixed to one or more members of the population of electrode structures, or one or more members of the population of counter-electrode structures.

14. The structure according to claim 13 , wherein the first and second primary connecting members are affixed to one or more members of the population of electrode structures, or one or more members of the population of counter-electrode structures, by any one or more of adhering, gluing, welding, bonding, soldering, sintering, press contacting, brazing, thermal spraying joining, clamping, wire bonding, ribbon bonding, ultrasonic bonding, ultrasonic welding, resistance welding, laser beam welding, electron beam welding, induction welding, cold welding, plasma spraying, flame spraying, and arc spraying.

15. The structure according to claim 1 , wherein the first and second primary connecting members each comprise a thickness that is less than 20% of a first height of a first member of the population of electrode structures or a first height of a first member of the population of counter-electrode structures.

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

17. The structure according to claim 1 , wherein at least a portion of the constraint comprises stainless steel, aluminum, titanium, beryllium copper, copper, nickel, alumina, zirconia, yttria-stabilized zirconia, Schott D263 tempered glass, polyetheretherketone (PEEK), PEEK with carbon, polyphenylene sulfide (PPS) with carbon, polyetheretherketone (PEEK) with 30% glass, polyimide, E Glass Std Fabric/Epoxy, E Glass UD/Epoxy, Kevlar Std Fabric/Epoxy, Kevlar UD/Epoxy, Carbon Std Fabric/Epoxy, Carbon UD/Epoxy, Toyobo Zylon® HM Fiber/Epoxy, Kevlar 49 Aramid Fiber, S Glass Fibers, Carbon Fibers, Vectran UM LCP Fibers, Dyneema, and Zylon, or any combinations thereof.

18. The structure according to claim 1 , wherein the constraint maintains the pressure on the electrode assembly in the stacking direction that exceeds the additional pressure maintained on the electrode assembly in each of the transverse direction and the vertical direction during cycling of the electrode assembly between the charged and the discharged state by a factor of at least two (2).

19. The structure according to claim 1 , wherein the constraint maintains the pressure on the electrode assembly in the stacking direction that exceeds the additional pressure maintained on the electrode assembly in each of the transverse direction and the vertical direction during cycling of the electrode assembly between the charged and the discharged state by a factor of at least three (3).

20. The structure according to claim 1 , wherein the constraint maintains the pressure on the electrode assembly in the stacking direction that exceeds the additional pressure maintained on the electrode assembly in each of the transverse direction and the vertical direction during cycling of the electrode assembly between the charged and the discharged state by a factor of at least four (4).

Assignments (3)
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Apr 7, 2025
From: BUSACCA, ROBERT S.; LAHIRI, ASHOK; RAMASUBRAMANIAN, MURALI; VALDES, BRUNO A.; DALES, GARDNER CAMERON; SPINDT, CHRISTOPHER J.; HO, GEOFFREY MATTHEW; RUST, HARROLD J., III; WILCOX, JAMES D.; VARNI, JOHN F.; LEE, KIM HAN; SHAH, NIRAV S.; CONTRERAS, RICHARD J.; ERDEN, LYNN VAN; DIOUMAEV, VLADIMIR
To: ENOVIX CORPORATION
Reel/Frame 070751/0584 →
MERGER AND CHANGE OF NAME Recorded Apr 7, 2025
From: ENOVIX OPERATIONS INC.; ENOVIX CORPORATION
To: ENOVIX CORPORATION
Reel/Frame 070751/0649 →
MERGER AND CHANGE OF NAME Recorded Apr 7, 2025
From: RSVAC MERGER SUB INC.; ENOVIX CORPORATION; ENOVIX OPERATIONS INC.
To: ENOVIX OPERATIONS INC.
Reel/Frame 070751/0654 →
Continuity (8)
Continuation 17903250 · Sep 6, 2022
Continuation 17335725 · Jun 1, 2021
Continuation 16241159 · Jan 7, 2019
Continuation 15889338 · Feb 6, 2018
Continuation PCTUS2017032355 · May 12, 2017
Provisional Application 62422958 · Nov 16, 2016
Provisional Application 62335912 · May 13, 2016
Related Publication 20240291012A1 · Aug 29, 2024
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