Abstract: A secondary battery for cycling between a charged and a discharged state, comprises a battery enclosure, an electrode assembly, carrier ions, and an electrolyte, wherein the electrode assembly comprises a population of unit cells, each unit cell comprising, in a stacking direction, a unit cell portion of an electrode current collector layer, an electrode layer comprising electrode active material, a separator layer, a counter-electrode layer and a unit cell portion of a counter-electrode current collector layer, and a subset of the members of the unit cell population comprises a population of spacer structures located in the stacked succession, and for each member of unit cell population subset there exists an imaginary line that extends in a direction that is orthogonal to the stacking direction and intersects the counter-electrode layer and at least one member of the spacer structure population comprised by each respective member of the unit cell population subset.

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%.

Abstract: “electrode assembly having a porous electrically insulating material, and first and second endplates. The electrode assembly comprises opposing first and second longitudinal end surfaces separated along a stacking direction of an electrode and a counter electrode of the electrode assembly. First and second endplates are separated in the stacking direction and overlie the first and second longitudinal end surfaces.

Abstract: Production of electrodes, electrode assemblies, electrode stacks, and batteries, is disclosed herein comprising merging webs, associated devices, methods, and control such as relating to battery manufacturing. The batteries can comprise electrochemical active material. The webs can comprise weakened tear features for delineation components of the electrodes, electrode assemblies, electrode stack, and for the batteries.

Abstract: An electrode assembly includes unit cells stacked in a stacking direction, each including an electrode structure, a separator structure, and a counter-electrode structure. The electrode structure includes an electrode current collector and an electrode active material layer, the electrode structure extends in a longitudinal direction perpendicular to the stacking direction, an end portion of the electrode current collector extends past an outer surface of the electrode active material layer and the separator structure. The electrode assembly further includes an adhesive layer including a resistive polymeric material, and an electrode busbar attached to the end portions of the electrode current collectors through the adhesive layer.

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: 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 for cycling between a charged and a discharged state is provided. The secondary battery has an electrode assembly having a population of anode structures, a population of cathode structures, and an electrically insulating microporous separator material. The electrode assembly also has a set of electrode constraints that at least partially restrains growth of the electrode assembly. Members of the anode structure population have a first cross-sectional area, A1 when the secondary battery is in the charged state and a second cross-sectional area, A2, when the secondary battery is in the discharged state, and members of the cathode structure population have a first cross-sectional area, C1 when the secondary battery is in the charged state and a second cross-sectional area, C2, when the secondary battery is in the discharged state, where A1 is greater than A2, and C1 is less than C2.

Abstract: A secondary battery cell chargeable between a charged state and a discharged state is provided. The secondary battery cell comprises an electrode current collector having (a) an electrode current collector body region and (b) an electrode current collector end region having a smaller height than the electrode current collector body.

Abstract: A method for manufacturing a structure comprising and electrode assembly having a porous electrically insulating material, and first and second endplates, is provided. The electrode assembly comprises a population of unit cells stacked in series in a stacking direction, opposing first and second longitudinal end surfaces separated along the stacking direction. First and second endplates are separated in the stacking direction and overlie the first and second longitudinal end surfaces. According to embodiments of the structure, (i) each unit cell comprises an electrode structure, a counter-electrode structure, and an electrically insulating separator between the electrode and counter-electrode structures, (ii) the electrode structures, counter-electrode structures and electrically insulating separators within each unit cell have opposing first and second vertical end surfaces separated in a vertical direction, and (iii) the vertical direction is orthogonal to the stacking direction.

Abstract: A method includes stacking unit cells in a stacking direction. Each unit cell includes an electrode structure, a separator structure, and a counter-electrode structure. The electrode structure includes an electrode current collector and an electrode active material layer, and the counter-electrode structure includes a counter-electrode current collector and a counter-electrode active material layer. The electrode and counter-electrode structures extend in a longitudinal direction perpendicular to the stacking direction, and an end portion of the electrode current collector extends past the electrode active material and the separator structure in the longitudinal direction.

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 secondary battery for cycling between a charged and a discharged state is provided. The secondary battery has an electrode assembly having a population of anode structures, a population of cathode structures, and an electrically insulating microporous separator material. The electrode assembly also has a set of electrode constraints that at least partially restrains growth of the electrode assembly. Members of the anode structure population have a first cross-sectional area, A1 when the secondary battery is in the charged state and a second cross-sectional area, A2, when the secondary battery is in the discharged state, and members of the cathode structure population have a first cross-sectional area, C1 when the secondary battery is in the charged state and a second cross-sectional area, C2, when the secondary battery is in the discharged state, where A1 is greater than A2, and C1 is less than C2.

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%.

Abstract: An energy storage device, the energy storage device including a constraint that maintains a pressure on a unit cell configured for energy storage, e.g., during use of the unit cell.

Abstract: A method includes stacking unit cells in a stacking direction. Each unit cell includes an electrode structure, a separator structure, and a counter-electrode structure. The electrode structure includes an electrode current collector and an electrode active material layer, and the counter-electrode structure includes a counter-electrode current collector and a counter-electrode active material layer. The electrode and counter-electrode structures extend in a longitudinal direction perpendicular to the stacking direction, and an end portion of the electrode current collector extends past the electrode active material and the separator structure in the longitudinal direction.

Abstract: Unit cells for use in electrical current conductance, the electrode structure comprising an electrode separated from a counter electrode by a separator, the unit cell being configured to accommodate expansion of electrode active material during a second use of the device e.g., at least in part by using spacer structures.

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 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%.