Electrically coupled electrodes, and associated articles and methods
Methods for electrically coupling electrode portions within electrochemical devices, and associated articles and systems, are generally described. In some cases, an electrically non-conductive layer is between multiple electrode portions that are to be coupled. In some cases, the method comprises penetrating the article to establish electrical coupling between the electrode portions previously separated by the electrically non-conductive layer.
1. A method comprising:
penetrating a portion of an article comprising:
an electrically non-conductive layer comprising a first side and a second side that is penetrated during the penetrating;
a first electrode portion adjacent to the first side of the electrically non-conductive layer, wherein the first electrode portion comprises a first electrode active material that is an electrochemically active species that is penetrated during the penetrating; and
a second electrode portion adjacent to the second side of the electrically non-conductive layer, wherein the second electrode portion comprises a second electrode active material that is an electrochemically active species that is penetrated during the penetrating, such that the penetrating causes the formation of an electrically conductive solid material region extending from the first electrode portion, through the electrically non-conductive layer, and to the second electrode portion,
wherein:
the first electrode active material of the first electrode portion is the same as the second electrode active material of the second electrode portion,
the electrically conductive solid material region also comprises electrode active material that is the same as the electrode active material present in the first electrode portion and the second electrode portion, and
the electrically conductive solid material region electrically couples the first electrode portion and the second electrode portion.
2. The method of claim 1 , wherein the penetrating comprises piercing the article with a solid object.
3. The method of claim 2 , wherein the solid object is or comprises a pin.
4. The method of claim 2 , further comprising removing the solid object.
5. The method of claim 1 , wherein the first electrode portion has a polarity, and the second electrode portion has a polarity that is the same as the polarity of the first electrode portion.
6. The method of claim 5 , wherein a portion of the first electrode portion or the second electrode portion is covered by a third electrode portion, wherein the third electrode portion has a polarity that is opposite of the polarity of the first electrode portion and the second electrode portion.
7. The method of claim 1 , wherein the penetrating causes the formation of a cavity extending from the first electrode portion, through the electrically non-conductive layer, and to the second electrode portion.
8. The method of claim 7 , wherein at least a portion of the electrically conductive solid material is positioned along a wall of the cavity.
9. The method of claim 7 , further comprising filling at least a portion of the cavity with an electrically conductive material.
10. The method of claim 7 , wherein the cavity has a cross-section perpendicular to its length, and the ratio of the perimeter of the cross-section to the area of the cross-section is greater than or equal to 1 mm −1 and less than or equal to 30 mm −1 .
11. The method of claim 7 , wherein the cavity is a first cavity, and the article further comprises a second cavity.
12. The method of claim 7 , wherein the article comprises a first side and a second side opposite the first side, and the cavity extends from the first side to the second side.
13. The method of claim 1 , wherein the first electrode active material, the second electrode active material, and the electrically conductive solid material region comprise lithium metal.
14. The method of claim 13 , wherein the lithium metal is part of a lithium metal alloy.
15. The method of claim 1 , wherein the electrically conductive solid material region has a cross-section perpendicular to its length, and the ratio of the perimeter of the cross-section to the area of the cross-section is greater than or equal to 1 mm −1 and less than or equal to 30 mm −1 .
16. The method of claim 1 , wherein the electrically non-conductive layer, the first electrode portion, and the second electrode portion form a first double-sided electrode portion, and the article further comprises a second double-sided electrode portion adjacent to the first double-sided electrode portion.
17. The method of claim 16 , wherein:
the penetrating causes the formation of an electrically conductive solid material region extending from the first electrode portion, through the electrically non-conductive layer, and to the second electrode portion, wherein the electrically conductive solid material region electrically couples the first electrode portion and the second electrode portion; and
the first double-sided electrode portion is electrically coupled to the second double-sided electrode portion by the electrically conductive solid material region.
18. The method of claim 16 , wherein:
the penetrating causes the formation of a cavity extending from the first electrode portion, through the electrically non-conductive layer, and to the second electrode portion; and
the cavity extends through the first double-sided electrode portion and the second double-sided electrode portion in a direction normal to the first side and the second side of each electrically non-conductive layer.
19. The method of claim 16 , wherein:
the penetrating causes the formation of an electrically conductive solid material region extending from the first electrode portion, through the electrically non-conductive layer, and to the second electrode portion, wherein the electrically conductive solid material region electrically couples the first electrode portion and the second electrode portion; and
the electrically conductive solid material region extends through the first double-sided electrode portion and the second double-sided electrode portion in a direction normal to the first side and the second side of each electrically non-conductive layer.
20. The method of claim 16 , further comprising a third electrode portion disposed between a portion of the first double-sided electrode portion and a portion of the second double-sided electrode portion, wherein the third electrode portion has a polarity that is different than the polarity of an electrode portion of the first double-sided electrode portion and an electrode portion of the second double-sided electrode portion.
21. The method of claim 1 , wherein the electrically conductive solid material region is a first electrically conductive solid material region, and the article further comprises a second electrically conductive solid material region.
22. The method of claim 1 , wherein the article comprises a first side and a second side opposite the first side, and the electrically conductive solid material region extends from the first side to the second side.
23. The method of claim 1 , wherein the electrically non-conductive layer comprises a release layer.
24. The method of claim 1 , further comprising a liquid electrolyte in electrochemical communication with the first electrode portion and/or the second electrode portion.
25. The method of claim 1 , wherein the article is a part of an electrochemical device.
26. The method of claim 25 , wherein the article is electrically coupled to an electrically conductive terminal of the electrochemical device.
27. The method of claim 25 , wherein the electrochemical device is part of a rechargeable battery.
28. The method of claim 25 , wherein the electrochemical device is a part of an electric vehicle.
29. A method comprising:
penetrating a portion of an article comprising:
an electrically non-conductive layer comprising a first side and a second side that is penetrated during the penetrating;
a first electrode portion adjacent to the first side of the electrically non-conductive layer, wherein the first electrode portion comprises a first electrode active material that is an electrochemically active species that is penetrated during the penetrating; and
a second electrode portion adjacent to the second side of the electrically non-conductive layer, wherein the second electrode portion comprises a second electrode active material that is an electrochemically active species that is penetrated during the penetrating,
such that an electrical coupling between the first electrode portion and the second electrode portion is established, wherein the penetrating causes the formation of a cavity extending from the first electrode portion, through the electrically non-conductive layer, and to the second electrode portion; and
filling at least a portion of the cavity with an electrically conductive material.
30. The method of claim 29 , wherein the first electrode active material comprises lithium metal.
31. The method of claim 30 , wherein the second electrode active material comprises lithium metal.
32. A method comprising:
penetrating a portion of an article by piercing the article with a solid object, wherein the article comprises:
an electrically non-conductive layer comprising a first side and a second side that is penetrated during the penetrating;
a first electrode portion adjacent to the first side of the electrically non-conductive layer, wherein the first electrode portion comprises a first electrode active material that is an electrochemically active species that is penetrated during the penetrating; and
a second electrode portion adjacent to the second side of the electrically non-conductive layer, wherein the second electrode portion comprises a second electrode active material that is an electrochemically active species that is penetrated during the penetrating,
such that an electrical coupling between the first electrode portion and the second electrode portion is established; and
removing the solid object.
33. The method of claim 32 , wherein the first electrode active material comprises lithium metal.
34. The method of claim 33 , wherein the second electrode active material comprises lithium metal.
35. A method comprising:
penetrating a portion of an article comprising:
an electrically non-conductive layer comprising a first side and a second side that is penetrated during the penetrating;
a first electrode portion adjacent to the first side of the electrically non-conductive layer, wherein the first electrode portion comprises a first electrode active material that is an electrochemically active species that is penetrated during the penetrating; and
a second electrode portion adjacent to the second side of the electrically non-conductive layer, wherein the second electrode portion comprises a second electrode active material that is an electrochemically active species that is penetrated during the penetrating,
such that an electrical coupling between the first electrode portion and the second electrode portion is established, and
wherein the electrically non-conductive layer, the first electrode portion, and the second electrode portion form a first double-sided electrode portion, and the article further comprises a second double-sided electrode portion adjacent to the first double-sided electrode portion.
36. The method of claim 35 , wherein the penetrating causes the formation of an electrically conductive solid material region extending from the first electrode portion, through the electrically non-conductive layer, and to the second electrode portion, wherein the electrically conductive solid material region electrically couples the first electrode portion and the second electrode portion.
37. The method of claim 35 , wherein the first electrode active material of the first electrode portion is the same as the second electrode active material of the second electrode portion.
38. The method of claim 1 , wherein the first electrode active material and the second electrode active material comprise lithium metal.
39. The method of claim 38 , wherein the lithium metal is part of a lithium metal alloy.
40. The method of claim 35 , wherein the first electrode active material comprises lithium metal.
41. The method of claim 40 , wherein the lithium metal is part of a lithium metal alloy.
42. The method of claim 35 , wherein the second electrode active material comprises lithium metal.
43. The method of claim 42 , wherein the lithium metal is part of a lithium metal alloy.