Abstract: A compression fixture includes a base and a plurality of compression plate sets coupled to the base. Each compression plate set includes a fixed compression plate, a moveable compression plate, and at least one spring coupled to the moveable compression plate. The moveable compression plate is moveable relative to the fixed compression plate between a first position and a second position in which the moveable compression plate is positioned farther from the fixed compression plate than in the first position. The fixed compression plate and the moveable compression plate define a battery receptacle therebetween for receiving a lithium containing secondary battery. The at least one spring biases the moveable compression plate towards the fixed compression plate such that a compressive force is applied to the lithium containing secondary battery when positioned within the battery receptacle. The compression fixture may be incorporated into a cell formation system for lithium containing secondary batteries.

Abstract: An apparatus for merging webs for the production of an electrode assembly for a secondary battery includes first and second webs of base material wound on a first spool and a second spool, respectively. The apparatus also includes first and second rotating assemblies configured to move the first and second webs of base material along a first web merge path and a second web merge path, respectively. The first and second rotating assemblies are configured to control a tension of the respective web of base material in a down web direction along a portion of the respective web merge path located between the respective spool and rotating assembly. The apparatus also includes a receiving member configured to receive the first and second webs of base material at first and second web merge locations, respectively, such that the second web of base material overlays the first web of base material.

Abstract: An apparatus for merging webs for the production of an electrode assembly for a secondary battery includes first and second webs of base material wound on a first spool and a second spool, respectively. The apparatus also includes first and second rotating assemblies configured to move the first and second webs of base material along a first web merge path and a second web merge path, respectively. The first and second rotating assemblies are configured to control a tension of the respective web of base material in a down web direction along a portion of the respective web merge path located between the respective spool and rotating assembly. The apparatus also includes a receiving member configured to receive the first and second webs of base material at first and second web merge locations, respectively, such that the second web of base material overlays the first web of base material.

Abstract: A secondary battery assembly includes an electrode assembly having mutually perpendicular transverse, longitudinal, and vertical axes corresponding to the X, Y and Z axes, respectively, of a three-dimensional Cartesian coordinate system. The electrode assembly defines a population of faces, each face defined by two of the transverse, longitudinal, and vertical axes. The secondary battery assembly also includes a population of first current collector tabs electrically coupled to a first bus bar extending along a first face of the electrode assembly, the first face extending in at least one of a Z-X plane defined by the Z and X axes or a Z-Y plane defined by the Z and Y axes. The second battery assembly also includes a reinforcement structure disposed over at least a portion of the first current collector tabs, the first current collector tabs extending along the first face. The reinforcement structure includes a polymer.

Abstract: A secondary battery assembly includes an electrode assembly having mutually perpendicular transverse, longitudinal, and vertical axes corresponding to X, Y and Z axes, respectively. A constraint is disposed on an outer surface of the electrode assembly. At least one of the electrode assembly or constraint has a protrusion extending in an X-Y plane defined by the X and Y axes and having a first radius of curvature in the X-Y plane. A battery enclosure encloses the electrode assembly and the constraint. An enclosure protection layer is disposed over at least a portion of the protrusion and between the protrusion and the battery enclosure. The enclosure protection layer defines a second radius of curvature overlying the first radius of curvature in the X-Y plane. The second radius of curvature is greater than the first radius of curvature to thereby reduce the potential of the protrusion causing damage to the battery enclosure.

Abstract: A process for merging webs for the production of an electrode assembly for a secondary battery, the process comprising: moving a first web comprising a population of first components for electrode sub-units, the first components delineated by corresponding weakened patterns, and a population of first conveying features. Moving a second web comprising a population of second components for the electrode sub-units, the second components delineated by corresponding weakened patterns, and a population of second conveying features. Conveying a receiving member, the receiving member comprising a plurality of projections. Receiving the first web on the receiving member. Overlaying, the second web on the first web such that the first components are aligned with the second components and the conveying features of the second web are engaged by the plurality of projections on the receiving member. The second web merge location being spaced from the first web merge location.

Abstract: A process for merging webs for the production of an electrode assembly for a secondary battery, the process comprising: moving a first web comprising a population of first components for electrode sub-units, the first components delineated by corresponding weakened patterns, and a population of first conveying features. Moving a second web comprising a population of second components for the electrode sub-units, the second components delineated by corresponding weakened patterns, and a population of second conveying features. Conveying a receiving member, the receiving member comprising a plurality of projections. Receiving the first web on the receiving member. Overlaying, the second web on the first web such that the first components are aligned with the second components and the conveying features of the second web are engaged by the plurality of projections on the receiving member. The second web merge location being spaced from the first web merge location.