CN117083728A

CN117083728A - Electrochemical cell with enhanced current collector and method of producing the same

Info

Publication number: CN117083728A
Application number: CN202280025290.8A
Authority: CN
Inventors: 草地雄树; 太田直树; 陈君政
Original assignee: 24M Technologies Inc
Current assignee: 24M Technologies Inc
Priority date: 2021-03-30
Filing date: 2022-03-29
Publication date: 2023-11-17

Abstract

Embodiments described herein relate to electrochemical cells and electrodes with enhanced current collectors. In some embodiments, an electrode may include a current collector and an electrode material disposed on a first side of the current collector. The reinforcing layer may be disposed on the second side of the current collector. The reinforcing layer may have a modulus of elasticity sufficient to reduce the amount of stretch created on the current collector during operation of the electrode. In some embodiments, a polymer film may be disposed on the reinforcing material. In some embodiments, the electrode may further comprise an adhesive polymer disposed between the reinforcing material and the polymer film. In some embodiments, the reinforcing material may have a thickness of less than about 10 μm. In some embodiments, the reinforcing layer may comprise an adhesive polymer.

Description

Electrochemical cell with enhanced current collector and method of producing the same

Cross Reference to Related Applications

The present application claims priority and benefit from U.S. provisional application No. 63/167,741 filed on 3 months of 2021 and U.S. provisional application No. 63/249,863 filed on 29 months of 2021, both entitled "electrochemical cell with enhanced current collector and method of producing same (Electrochemical Cells with Reinforced Current Collectors and Methods of Producing the Same)", the disclosures of which are hereby incorporated by reference in their entireties.

Technical Field

Embodiments described herein relate to electrodes and electrochemical cells with enhanced current collectors and methods of their production.

Background

Embodiments described herein relate generally to electrochemical cells with enhanced current collectors. During operation, the components of the electrochemical cell may expand and contract. Such expansion and contraction may be due to temperature fluctuations in the battery as well as mechanical stimuli. The electrochemical material may be contained in an expanding and contracting assembly. The current collector coupled with the electrode material may also expand and contract. Expansion and contraction of the current collector material may cause wrinkles, gaps, discontinuities, and compressed portions to appear in the electrode material coupled to the current collector. Such defects may also occur in the current collector itself. These defects may interfere with battery life, rendering various portions of the electrode material unusable. Even current collector materials with high tensile strength or high elastic modulus may still inelastically deform, resulting in inelastic deformation in the electrode over time. Engineering current collector materials with high elastic moduli can be expensive. Systems that reduce the formation of such defects in the cell can maintain electrochemical cell performance.

Disclosure of Invention

Embodiments described herein relate to electrochemical cells and electrodes with enhanced current collectors. In some embodiments, an electrode may include a current collector and an electrode material disposed on a first side of the current collector. The reinforcing layer may be disposed on the second side of the current collector. The reinforcing layer may have a modulus of elasticity sufficient to reduce the amount of stretch created on the current collector during operation of the electrode. In some embodiments, a polymer film may be disposed on the reinforcing material. In some embodiments, the electrode may further comprise an adhesive polymer disposed between the reinforcing material and the polymer film. In some embodiments, the reinforcing material may have a thickness of less than about 10 μm. In some embodiments, the reinforcing layer may comprise an adhesive polymer. In some embodiments, an adhesive polymer may be disposed between the reinforcing material and the current collector. In some embodiments, the adhesive polymer disposed between the reinforcing material and the current collector may comprise at least one of an elastomer and a crosslinked polymer.

Drawings

Fig. 1 is a block diagram of an electrode with a current collector enhancement system according to one embodiment.

Fig. 2 is an illustration of an electrode with a current collector enhancement system according to one embodiment.

Fig. 3A-3B are illustrations of an electrode with a current collector enhancement system according to one embodiment.

Fig. 4A-4B are illustrations of an electrode with a current collector enhancement system according to one embodiment.

Fig. 5A-5B are illustrations of an electrode with a current collector enhancement system according to one embodiment.

Fig. 6 is an illustration of an electrode with a current collector enhancement system according to one embodiment.

Fig. 7A-7B are illustrations of an electrode having a current collector enhancement system according to one embodiment.

Fig. 8A-8B are illustrations of an electrode with a current collector enhancement system according to one embodiment.

Fig. 9 is an illustration of an electrochemical cell having a current collector enhancement system according to one embodiment.

Fig. 10 is a block diagram of a method of producing an electrode with a current collector enhancement system.

Detailed Description

Embodiments described herein relate to electrodes and electrochemical cells having current collector enhancement systems and methods of their production. In some embodiments, the electrochemical cells and electrodes may include a current collector having a reinforcing material coupled thereto. Enhanced current collectors may allow for the construction of electrodes with thinner current collectors. This allows for less current collector material to be used and reduces costs. Furthermore, electrochemical cells with enhanced current collectors can potentially have lower mass and increased energy and power density. In some embodiments, an electrochemical cell described herein can comprise a semi-solid cathode and/or a semi-solid anode. In some embodiments, the semi-solid electrodes described herein may be binder-free and/or may use less binder than is typically used in conventional battery fabrication. The semi-solid electrodes described herein may be formulated as a slurry such that the electrolyte is included in the slurry formulation. This is in contrast to conventional electrodes, such as calendered electrodes, in which an electrolyte is typically added to an electrochemical cell once the cell is disposed in a container, such as a pouch or can.

In some embodiments, the electrode materials described herein may be flowable semi-solid or concentrated liquid compositions. In some embodiments, the flowable semi-solid electrode may comprise a suspension of electrochemically active material (anode or cathode particles or microparticles) and optionally a conductive material (e.g., carbon) in a non-aqueous liquid electrolyte. In some embodiments, the active electrode particles and the conductive particles may be co-suspended in an electrolyte to produce a semi-solid electrode. In some embodiments, the electrode materials described herein may comprise conventional electrode materials (e.g., comprising lithium metal).

Examples of electrodes, electrolyte solutions, and methods that may be used to prepare them are described in U.S. patent No. 9,437,864 (hereinafter, "the' 864 patent"), entitled "asymmetric battery with semi-solid cathode and high energy density anode (Asymmetric Battery Having aSemi-Solid Cathode and High Energy Density Anode)", filed on 3/10/2014, the entire disclosure of which is hereby incorporated by reference. Further examples of electrodes, electrolyte solutions, and methods that may be used to prepare them are described in U.S. patent No. 9,484,569 (hereinafter referred to as the "569 patent") entitled "electrochemical paste composition and method of preparation thereof (Electrochemical Slurry Compositions and Methods for Preparing the Same)" filed on 3,15, 2013, 11, 4, and U.S. patent publication No. 2016/0133716 (hereinafter referred to as the "916 publication") entitled "electrochemical cell with Semi-solid electrode and method of manufacture thereof (Electrochemical Cells Having Semi-Solid Electrodes and Methods of Manufacturing the Same)", and U.S. patent No. 8,993,159 (hereinafter referred to as the "Semi-solid electrode with high rate capability (Semi-Solid Electrodes Having High Rate Capability)", filed on 4, 29, 2013, the entire disclosures of which are hereby incorporated by reference.

In some embodiments, the electrodes and electrochemical cells herein may comprise a current collector of reduced size. In other words, the current collector may cover only a portion of the electrode material coupled with the current collector. Examples of electrodes having current collectors covering only a portion of the adjacent electrode material are described in U.S. patent application Ser. No. 17/181,554 (hereinafter the' 554 application), the entire disclosure of which is hereby incorporated by reference, entitled "electrochemical cells having electrode materials directly coupled to a membrane and methods of making same (Electrochemical Cells with Electrode Material Coupled Directly to Film and Methods of Making the Same)", filed on 22, 2021.

As used in this specification, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise. Thus, for example, the term "member" is intended to mean a single member or a combination of members, and "material" is intended to mean one or more materials or a combination thereof.

The term "substantially" when used in connection with "cylindrical," "linear," and/or other geometric relationships is intended to convey that the structure so defined is nominally cylindrical, linear, etc. As an example, a portion of the support member described as "substantially linear" is intended to be representative, although linearity of that portion is desirable, some nonlinearity may occur in the "substantially linear" portion. Such non-linearities may result from manufacturing tolerances or other practical considerations such as, for example, pressure or force applied to the support member. Thus, a geometric construct modified by the term "substantially" encompasses such geometric properties within a tolerance of + -5% of the geometric construct. For example, a "substantially linear" portion is a portion defining an axis or centerline that is within + -5% of linearity.

As used herein, the terms "a set" and "a plurality" may refer to multiple features or a single feature having multiple portions. For example, when referring to a set of electrodes, the set of electrodes may be considered to be one electrode having multiple portions, or the set of electrodes may be considered to be multiple different electrodes. Further, for example, when referring to a plurality of electrochemical cells, the plurality of electrochemical cells may be considered as a plurality of different electrochemical cells or as one electrochemical cell having a plurality of portions. Thus, a set of portions or portions may comprise portions that are continuous or discontinuous with each other. The plurality of particles or materials may also be made from a plurality of articles that are produced separately and then bonded together (e.g., via mixing, adhesives, or any suitable method).

As used herein, the term "semi-solid" refers to a material that is a mixture of a liquid phase and a solid phase, such as, for example, a particle suspension, slurry, colloidal suspension, emulsion, gel, or micelle.

Fig. 1 is a block diagram of an electrode 100 having a current collector enhancement system according to one embodiment. As shown, electrode 100 includes an electrode material 110 disposed on a first side of a current collector 120 and a reinforcing layer 130 disposed on a second side of current collector 120, the second side being opposite the first side. In some embodiments, the electrode 100 may include a membrane material 140 disposed on the reinforcement layer 130.

In some embodiments, the electrode material 110 may comprise an anode material. In some embodiments, the electrode material 110 may comprise a cathode material. In some embodiments, the electrode material 110 may comprise silicon. In some embodiments, the electrode material 110 may comprise at least one high capacity anode material selected from silicon, bismuth, boron, gallium, indium, zinc, tin, antimony, aluminum, titanium oxide, molybdenum, germanium, manganese, niobium, vanadium, tantalum, iron, copper, gold, platinum, chromium, nickel, cobalt, zirconium, yttrium, molybdenum oxide, germanium oxide, silicon carbide, any other high capacity material or alloys thereof, and any combination thereof. In some embodiments, the electrode material 110 may comprise a silicon alloy, a tin alloy, aluminum, titanium oxide, or any combination thereof. In some embodiments, the electrode material 110 may comprise any of the materials described in the' 864 patent. In some embodiments, the electrode material 110 may comprise a semi-solid electrode material. In some embodiments, the electrode material 110 may be binder-free.

In some embodiments, the electrode material 110 may have a thickness of at least about 50 μm, at least about 100 μm, at least about 200 μm, at least about 300 μm, at least about 400 μm, at least about 500 μm, at least about 600 μm, at least about 700 μm, at least about 800 μm, at least about 900 μm, at least about 1,000 μm, at least about 1,100 μm, at least about 1,200 μm, at least about 1,300 μm, at least about 1,400 μm, at least about 1,500 μm, at least about 1,600 μm, at least about 1,700 μm, at least about 1,800 μm, or at least about 1,900 μm. In some embodiments, the electrode material 110 may have a thickness of no more than about 2,000 μm, no more than about 1,900 μm, no more than about 1,800 μm, no more than about 1,700 μm, no more than about 1,600 μm, no more than about 1,500 μm, no more than about 1,400 μm, no more than about 1,300 μm, no more than about 1,200 μm, no more than about 1,100 μm, no more than about 1,000 μm, no more than about 900 μm, no more than about 800 μm, no more than about 700 μm, no more than about 600 μm, no more than about 500 μm, no more than about 400 μm, no more than about 300 μm, no more than about 200 μm, or no more than about 100 μm. In some embodiments, the electrode material 110 may have a thickness of about 50 μm, about 100 μm, about 200 μm, about 300 μm, about 400 μm, about 500 μm, about 600 μm, about 700 μm, about 800 μm, about 900 μm, about 1,000 μm, about 1,100 μm, about 1,200 μm, about 1,300 μm, about 1,400 μm, about 1,500 μm, about 1,600 μm, about 1,700 μm, about 1,800 μm, about 1,900 μm, or about 2,000 μm.

In some embodiments, the electrode material 110 may comprise multiple layers. In some embodiments, the electrode material 110 may include a first layer having a first porosity and a second layer having a second porosity, the second porosity being different from the first porosity. In some embodiments, the anode material 110 may include a first layer having a first energy density and a second layer having a second energy density, the second energy density being different than the first energy density. An example of an electrode having a composition gradient is described in U.S. patent publication No. 2019/0363351 (hereinafter, "the' 351 publication"), entitled "High Energy density composition gradient electrode and method of making same" (High Energy-Density Composition-Gradient Electrodes and Methods of Making the Same), filed on 5.24, 2019, the entire disclosure of which is hereby incorporated by reference in its entirety.

In some embodiments, current collector 120 may be composed of copper, aluminum, titanium, or other metals that do not form alloys or intermetallic compounds with lithium, carbon, and/or coatings comprising these materials disposed on another conductor. In some embodiments, the current collector 120 may be made particularly thin because the reinforcement layer 130 provides additional support. In some embodiments, the current collector 120 may have a thickness of less than about 20 μm, less than about 19 μm, less than about 18 μm, less than about 17 μm, less than about 16 μm, less than about 15 μm, less than about 14 μm, less than about 13 μm, less than about 12 μm, less than about 11 μm, less than about 10 μm, less than about 9 μm, less than about 8 μm, less than about 7 μm, less than about 6 μm, less than about 5 μm, less than about 4 μm, less than about 3 μm, less than about 2 μm, or less than about 1 μm, including all values and ranges therebetween.

In some embodiments, the current collector 120 may include pores. The pores in the current collector 120 may further reduce the amount of current collector material contained in the electrode 100. In some embodiments, the holes may be arranged in a grid. In some embodiments, holes may be punched in the current collector 120. In some embodiments, the current collector 120 may have a porosity (i.e., a percentage of the surface area of the current collector 120 occupied by pores) of at least about 5%, at least about 10%, at least about 15%, at least about 20%, at least about 25%, at least about 30%, at least about 35%, at least about 40%, at least about 45%, at least about 50%, at least about 55%, at least about 60%, at least about 65%, at least about 70%, at least about 75%, at least about 80%, at least about 85%, or at least about 90%. In some embodiments, the current collector 120 may have a porosity of no more than about 95%, no more than about 90%, no more than about 85%, no more than about 80%, no more than about 75%, no more than about 70%, no more than about 65%, no more than about 60%, no more than about 55%, no more than about 50%, no more than about 45%, no more than about 40%, no more than about 35%, no more than about 30%, no more than about 25%, no more than about 20%, no more than about 15%, or no more than about 10%.

Combinations of the above porosities of the current collector 120 are also possible (e.g., at least about 5% and no more than about 95% or at least about 30% and no more than about 50%), including all values and ranges therebetween. In some embodiments, the current collector 120 may have a porosity of about 5%, about 10%, about 15%, about 20%, about 25%, about 30%, about 35%, about 40%, about 45%, about 50%, about 55%, about 60%, about 65%, about 70%, about 75%, about 80%, about 85%, about 90%, or about 95%.

Combinations of the above thicknesses of electrode material 110 are also possible (e.g., at least about 50 μm and no more than about 2,000 μm or at least about 150 μm and no more than about 500 μm), including all values and ranges therebetween.

In some embodiments, the reinforcing layer 130 may have a tensile strength of at least about 400MPa, at least about 450MPa, at least about 500MPa, at least about 550MPa, at least about 600MPa, at least about 650MPa, at least about 700MPa, or at least about 750 MPa. In some embodiments, the reinforcing layer 130 may have a tensile strength of no more than about 800MPa, no more than about 750MPa, no more than about 700MPa, no more than about 650MPa, no more than about 600MPa, no more than about 550MPa, no more than about 500MPa, or no more than about 450 MPa. Combinations of the above tensile strengths of the reinforcing layer 130 are also possible (e.g., at least about 400MPa and no more than about 800MPa or at least about 500MPa and no more than about 700 MPa), including all values and ranges therebetween. In some embodiments, the reinforcing layer 130 may have a tensile strength of about 400MPa, about 450MPa, about 500MPa, about 550MPa, about 600MPa, about 650MPa, about 700MPa, about 750MPa, or about 800 MPa.

In some embodiments, the reinforcing layer 130 may have an elastic modulus of at least about 50GPa, at least about 100GPa, at least about 150GPa, at least about 200GPa, at least about 250GPa, at least about 300GPa, at least about 350GPa, at least about 400GPa, at least about 450GPa, at least about 500GPa, at least about 550GPa, at least about 600GPa, at least about 650GPa, at least about 700GPa, at least about 750GPa, at least about 800GPa, at least about 850GPa, at least about 900GPa, or at least about 950 GPa. In some embodiments, the reinforcing layer 130 may have an elastic modulus of no more than about 1,000GPa, no more than about 950GPa, no more than about 900GPa, no more than about 850GPa, no more than about 800GPa, no more than about 750GPa, no more than about 700GPa, no more than about 650GPa, no more than about 600GPa, no more than about 550GPa, no more than about 500GPa, no more than about 450GPa, no more than about 400GPa, no more than about 350GPa, no more than about 300GPa, no more than about 250GPa, no more than about 200GPa, no more than about 150GPa, or no more than about 100 GPa. Combinations of the above-described elastic moduli of the reinforcing layer 130 are also possible (e.g., at least about 50GPa and no more than about 1,000GPa or at least about 400GPa and no more than about 600 GPa), including all values and ranges there between. In some embodiments, the reinforcing layer 130 may have an elastic modulus of about 50GPa, about 100GPa, about 150GPa, about 200GPa, about 250GPa, about 300GPa, about 350GPa, about 400GPa, about 450GPa, about 500GPa, about 550GPa, about 600GPa, about 650GPa, about 700GPa, about 750GPa, about 800GPa, about 850GPa, about 900GPa, about 950GPa, or about 1,000 GPa. In some embodiments, the reinforcing layer 130 may have a higher modulus of elasticity than the current collector 120.

In some embodiments, the reinforcement layer 130 may comprise sodium silicate, glass powder, ceramic powder, glass fibers, short glass fibers, long glass fibers, carbon nanotubes, carbon fibers, short carbon fibers, long carbon fibers, or any other suitable reinforcement material or combination thereof. In some embodiments, the reinforcing layer 130 may include an adhesive material or binder disposed therein. In some embodiments, the tacky material may comprise a tacky polymer. In some embodiments, the adhesive polymer may comprise a high strength adhesive polymer. In some embodiments, the reinforcing layer 130 may be coupled with the current collector 120 via an adhesive material. In other words, the adhesive material may be disposed between the reinforcing layer 130 and the current collector 120. In some embodiments, the tacky material disposed between the reinforcing layer 130 and the current collector 120 may comprise a polymeric binder or a high strength polymeric binder. In some embodiments, the adhesion between the reinforcement layer 130 and the current collector 120 may further limit the stretching of the current collector 120. In some embodiments, the use of an adhesive incorporated into the reinforcing layer 130 or disposed between the current collector 120 and the reinforcing layer 130 increases the overall tensile strength and elastic modulus of the reinforcing layer 130 and the current collector 120.

In some embodiments, the reinforcing layer 130 may partially or completely occupy the void space in the current collector 120 left by the pores in the current collector 120. In some embodiments, the reinforcement layer 130 may have a thickness of at least about 1 μm, at least about 5 μm, at least about 10 μm, at least about 15 μm, at least about 20 μm, at least about 25 μm, at least about 30 μm, at least about 35 μm, at least about 40 μm, at least about 45 μm, at least about 50 μm, at least about 55 μm, at least about 60 μm, at least about 65 μm, at least about 70 μm, at least about 75 μm, at least about 80 μm, at least about 85 μm, at least about 90 μm, or at least about 95 μm. In some embodiments, the reinforcement layer 130 can have a thickness of no more than about 100 μm, no more than about 95 μm, no more than about 90 μm, no more than about 85 μm, no more than about 80 μm, no more than about 75 μm, no more than about 70 μm, no more than about 65 μm, no more than about 60 μm, no more than about 55 μm, no more than about 50 μm, no more than about 45 μm, no more than about 40 μm, no more than about 35 μm, no more than about 30 μm, no more than about 25 μm, no more than about 20 μm, no more than about 15 μm, no more than about 10 μm, or no more than about 5 μm. Combinations of the above thicknesses of the reinforcing layer 130 are also possible (e.g., at least about 1 μm and no more than about 100 μm or at least about 20 μm and no more than about 40 μm), including all values and ranges therebetween. In some embodiments, the reinforcement layer 130 may have a thickness of about 1 μm, about 5 μm, about 10 μm, about 15 μm, about 20 μm, about 25 μm, about 30 μm, about 35 μm, about 40 μm, about 45 μm, about 50 μm, about 55 μm, about 60 μm, about 65 μm, about 70 μm, about 75 μm, about 80 μm, about 85 μm, about 90 μm, about 95 μm, or about 100 μm.

In some embodiments, the film material 140 may form a portion of a pouch. In some embodiments, the film material 140 may be a first film material and may be coupled with a second film material to form a pouch. In some embodiments, the pouch may be vacuum sealed such that the film material 140 applies a force to the reinforcing layer 130. Such forces may maintain the coupling of the reinforcing layer 130 to the current collector 120 and prevent the reinforcing layer 130 from separating from the current collector 120. In some embodiments, the film material 140 may provide further structural reinforcement to the reinforcement layer 130. In some embodiments, the film material may prevent peeling of the reinforcement layer 130. In some embodiments, the film material 140 may be coupled with the reinforcement layer 130 via an adhesive. In some embodiments, the film material 140 may be heat melted and laminated to the reinforcement layer 130.

In some embodiments, the membrane material 140 may comprise a three-layer structure, i.e., an intermediate layer sandwiched between an outer layer and an inner layer, wherein the inner layer is in contact with the electrode and the electrolyte. For example, the outer layer may comprise a nylon-based polymer film. The inner layer may comprise a polypropylene (PP) polymer film that is resistant to acid or other electrolyte attack and insoluble in the electrolyte solvent. The intermediate layer may comprise an aluminum (Al) foil. This construction allows the bag to have high mechanical flexibility and strength.

In some embodiments, the outer layer of the membrane material 140 may comprise a polymeric material, such as polyethylene terephthalate (PET), polybutylene terephthalate (PBT), nylon, high Density Polyethylene (HDPE), oriented polypropylene (o-PP), polyvinyl chloride (PVC), polyimide (PI), polysulfone (PSU), and any combination thereof. In some embodiments, the intermediate layer of film material 140 may comprise a metal layer (foil, substrate, film, etc.) comprising aluminum (Al), copper (Cu), stainless steel (SUS), and alloys thereof, or any combination thereof. In some embodiments, the inner layer of the film material 140 may comprise a material such as cast polypropylene (c-PP), polyethylene (PE), ethylene Vinyl Acetate (EVA), PET, polyvinyl acetate (PVA), polyamide (PA), acrylic adhesive, ultraviolet (UV)/Electron Beam (EB)/Infrared (IR) curable resin, and any combination thereof. In some embodiments, the membrane material 140 may comprise a non-flammable material, such as, for example, polyetheretherketone (PEEK), polyethylene naphthalate (PEN), polyethersulfone (PES), PI, polyphenylene sulfide (PPS), polyphenylene oxide (PPO), and any combinations thereof. In some embodiments, the film material 140 may comprise a coating or film of a flame retardant additive material, such as flame retardant PET. In some embodiments, the film material 140 comprises a two-layer structure, an outer layer and an inner layer. In some embodiments, the outer layer may comprise PET, PBT, or other materials as described above. In some embodiments, the inner layer may comprise PP, PE, or other materials described above. In some embodiments, the membrane material 140 may comprise a water barrier layer and/or a gas barrier layer. In some embodiments, the barrier layer may comprise a metal layer and/or an oxide layer. In some embodiments, it may be beneficial to include an oxide layer, as the oxide layer tends to be insulating and may prevent shorting within the cell.

In some embodiments, the film material 140 can have a thickness of at least about 1 μm, at least about 5 μm, at least about 10 μm, at least about 20 μm, at least about 30 μm, at least about 40 μm, at least about 50 μm, at least about 60 μm, at least about 70 μm, at least about 80 μm, at least about 90 μm, at least about 100 μm, at least about 110 μm, at least about 120 μm, at least about 130 μm, at least about 140 μm, at least about 150 μm, at least about 160 μm, at least about 170 μm, at least about 180 μm, or at least about 190 μm. In some embodiments, the film material 140 can have a thickness of no more than about 200 μm, no more than about 190 μm, no more than about 180 μm, no more than about 170 μm, no more than about 160 μm, no more than about 150 μm, no more than about 140 μm, no more than about 130 μm, no more than about 120 μm, no more than about 110 μm, no more than about 100 μm, no more than about 90 μm, no more than about 80 μm, no more than about 70 μm, no more than about 60 μm, no more than about 50 μm, no more than about 40 μm, no more than about 30 μm, no more than about 20 μm, no more than about 10 μm, no more than about 5 μm, or no more than about 1 μm.

Combinations of the above thicknesses of film material are also possible (e.g., at least about 1 μm and no more than about 100 μm or at least about 20 μm and no more than about 60 μm), including all values and ranges there between. In some embodiments, the film material 140 can have a thickness of about 1 μm, about 5 μm, about 10 μm, about 20 μm, about 30 μm, about 40 μm, about 50 μm, about 60 μm, about 70 μm, about 80 μm, about 90 μm, about 100 μm, about 110 μm, about 120 μm, about 130 μm, about 140 μm, about 150 μm, about 160 μm, about 170 μm, about 180 μm, about 190 μm, or about 200 μm.

In some embodiments, electrode 100 may be part of an electrochemical cell. In some embodiments, electrode 100 may be coupled to another electrode with a separator disposed therebetween to form an electrochemical cell.

Fig. 2 is an illustration of an electrode 200 with a current collector enhancement system according to one embodiment. As shown, electrode 200 includes an electrode material 210 disposed on a first side of a current collector 220 and a reinforcement layer 230 disposed on a second side of current collector 220, the second side being opposite the first side. A film material 240 is disposed on the reinforcement layer 230. In some embodiments, electrode material 210, current collector 220, reinforcing layer 230, and membrane material 240 may be the same or substantially similar to electrode material 110, current collector 120, reinforcing layer 130, and membrane material 140, respectively, as described above with reference to fig. 1. Accordingly, certain aspects of the electrode material 210, the current collector 220, the reinforcement layer 230, and the membrane material 240 are not described in greater detail herein.

As shown, the film material 240 is disposed on an outside surface of the reinforcement layer 230. In some embodiments, the film material 240 and the reinforcement layer 230 may be combined into a single layer of reinforcement bag material. In some embodiments, a single layer of material may provide both the anti-contamination function and the structural reinforcement function of the current collector 220. As shown, the reinforcing layer 230 is disposed on the outer side surface of the current collector 220. In some embodiments, the reinforcement layer 230 and the current collector 220 may be combined into a single conductive and reinforcement material composite layer.

Fig. 3A-3B are illustrations of an electrode 300 having a current collector enhancement system according to one embodiment. Fig. 3A shows a cross-sectional view of electrode 300, while fig. 3B shows an exploded view of the components of electrode 300. As shown, electrode 300 includes electrode material 310 disposed on a first side of current collector 320 and a reinforcing layer 330 disposed on a second side of current collector 320, the second side being opposite the first side. A film material 340 is disposed on the reinforcement layer 330. The current collector 320 includes holes 322 and the reinforcing material 330 includes protrusions 331 penetrating the holes 322. In some embodiments, electrode material 310, current collector 320, reinforcing layer 330, and membrane material 340 may be the same or substantially similar to electrode material 110, current collector 120, reinforcing layer 130, and membrane material 140, as described above with reference to fig. 1. Accordingly, certain aspects of the electrode material 310, the current collector 320, the reinforcing layer 330, and the film material 340 are not described in greater detail herein.

As shown, the apertures 322 are arranged in a grid configuration with the rows and columns parallel to one another. In some embodiments, the apertures 322 of each row may be parallel to one another, while the apertures 322 of each column are arranged in a staggered configuration. In some embodiments, the apertures 322 of each column may be parallel to one another, while the apertures 322 of each row are arranged in a staggered configuration. In some embodiments, the apertures 322 may be arranged to maximize the structural integrity of the current collector 320. In some embodiments, the apertures 322 may further reduce wrinkling or other deformation of the electrode material 310 by allowing excess portions of the electrode material 310 to at least partially penetrate the apertures 322.

In some embodiments, the pores 322 may have a diameter of at least about 1 μm, at least about 5 μm, at least about 10 μm, at least about 20 μm, at least about 30 μm, at least about 40 μm, at least about 50 μm, at least about 60 μm, at least about 70 μm, at least about 80 μm, at least about 90 μm, at least about 100 μm, at least about 200 μm, at least about 300 μm, at least about 400 μm, at least about 500 μm, at least about 600 μm, at least about 700 μm, at least about 800 μm, or at least about 900 μm. In some embodiments, the aperture 322 may have a diameter of no more than about 1,000 μm, no more than about 900 μm, no more than about 800 μm, no more than about 700 μm, no more than about 600 μm, no more than about 500 μm, no more than about 400 μm, no more than about 300 μm, no more than about 200 μm, no more than about 100 μm, no more than about 90 μm, no more than about 80 μm, no more than about 70 μm, no more than about 60 μm, no more than about 50 μm, no more than about 40 μm, no more than about 30 μm, no more than about 20 μm, no more than about 10 μm, or no more than about 5 μm.

Combinations of the above diameters of the apertures 322 are also possible (e.g., at least about 1 μm and no more than about 1,000 μm or at least about 50 μm and no more than about 100 μm), including all values and ranges there between. In some embodiments, the pores 322 may have a diameter of about 1 μm, about 5 μm, about 10 μm, about 20 μm, about 30 μm, about 40 μm, about 50 μm, about 60 μm, about 70 μm, about 80 μm, about 90 μm, about 100 μm, about 200 μm, about 300 μm, about 400 μm, about 500 μm, about 600 μm, about 700 μm, about 800 μm, about 900 μm, or about 1,000 μm. In some embodiments, the holes 322 may have a uniform or substantially uniform diameter. In some embodiments, the holes 322 may have different diameters. In some embodiments, the apertures 322 may have a polydisperse diameter distribution.

As shown, the protrusions 331 of the reinforcing layer 330 completely penetrate the holes 322 to physically contact the electrode material 310. In some embodiments, the protrusions 331 of the reinforcement layer 330 may partially penetrate the holes 322. In some embodiments, the surface of the reinforcing material 330 adjacent to the current collector 320 may be flush with the current collector 320 such that substantially no portion of the reinforcing layer 330 penetrates into the aperture 322. In other words, the protrusions 331 may be flat, or the reinforcing layer 330 may be free of protrusions 331.

Fig. 4A-4B are illustrations of an electrode 400 having a current collector enhancement system according to one embodiment. Fig. 4A shows a cross-sectional view of electrode 400, while fig. 4B shows an exploded view of the components of electrode 400. As shown, electrode 400 includes electrode material 410 disposed on a first side of current collector 420 and reinforcing layer 430 disposed on a second side of current collector 420, the second side being opposite the first side. A film material 440 is disposed on the reinforcement layer 430. The current collector 420 includes holes 422, and the reinforcing material 430 includes protrusions 431 penetrating the holes 422. In some embodiments, electrode material 410, current collector 420, aperture 422, reinforcing layer 430, protrusion 431, and membrane material 440 may be the same as or substantially similar to electrode material 310, current collector 320, aperture 322, reinforcing layer 330, protrusion 331, and membrane material 340, respectively, as described above with reference to fig. 3A-3B. Accordingly, certain aspects of electrode material 410, current collector 420, aperture 422, reinforcing layer 430, protrusions 431, and film material 440 are not described in greater detail herein.

As shown, the protrusions 431 of the reinforcing layer partially penetrate the holes 422 such that the protrusions 431 do not penetrate the entire thickness of the current collector 420. Void space 421 is shown between the edges of protrusions 431 and the edges of current collector 420. In some embodiments, the protrusions 431 may penetrate at least about 5%, at least about 10%, at least about 15%, at least about 20%, at least about 25%, at least about 30%, at least about 35%, at least about 40%, at least about 45%, at least about 50%, at least about 55%, at least about 60%, at least about 65%, at least about 70%, at least about 75%, at least about 80%, at least about 85%, or at least about 90% of the thickness of the current collector 420. In some embodiments, protrusion 431 may penetrate no more than about 95%, no more than about 90%, no more than about 85%, no more than about 80%, no more than about 75%, no more than about 70%, no more than about 65%, no more than about 60%, no more than about 55%, no more than about 50%, no more than about 45%, no more than about 40%, no more than about 35%, no more than about 30%, no more than about 25%, no more than about 20%, no more than about 15%, or no more than about 10% of the thickness of current collector 420.

Combinations of the above percentages of the thickness of the current collector 420 penetrated by the protrusions 431 are also possible (e.g., at least about 5% and no more than about 95% or at least about 30% and no more than about 60%), including all values and ranges therebetween. In some embodiments, the protrusion 431 may penetrate about 5%, about 10%, about 15%, about 20%, about 25%, about 30%, about 35%, about 40%, about 45%, about 50%, about 55%, about 60%, about 65%, about 70%, about 75%, about 80%, about 85%, about 90%, or about 95% of the thickness of the current collector 420.

Fig. 5A-5B are illustrations of an electrode 500 having a current collector enhancement system according to one embodiment. Fig. 5A shows a cross-sectional view of electrode 500, while fig. 5B shows an exploded view of the components of electrode 500. As shown, electrode 500 includes an electrode material 510 disposed on a first side of a current collector 520 and a reinforcing layer 530 disposed on a second side of current collector 520, the second side being opposite the first side. A film material 540 is disposed on the reinforcement layer 530. The current collector 520 includes holes 522, and the reinforcing material 530 includes protrusions 531 penetrating the holes 522. The electrode material 510 further includes protrusions 511 penetrating the holes 522. In some embodiments, electrode material 510, current collector 520, aperture 522, reinforcing layer 530, protrusion 531, and film material 540 may be the same as or substantially similar to electrode material 410, current collector 420, aperture 422, reinforcing layer 430, protrusion 431, and film material 440, as described above with reference to fig. 4A-4B. Accordingly, certain aspects of the electrode material 510, current collector 520, aperture 522, reinforcing layer 530, protrusion 531, and film material 540 are not described in greater detail herein.

As shown, the protrusions 511 of the electrode material 510 and the protrusions 531 of the reinforcing layer 530 meet at points along the thickness of the current collector 520. In some embodiments, the junction of the protrusion 511 of the electrode material 510 and the protrusion 531 of the reinforcing layer 530 may be approximately midway between the thicknesses of the current collectors 520. In some embodiments, the intersection of the protrusions 511 of the electrode material 510 and the protrusions 531 of the reinforcing layer 530 may be at about 5%, about 10%, about 15%, about 20%, about 25%, about 30%, about 35%, about 40%, about 45%, about 50%, about 55%, about 60%, about 65%, about 70%, about 75%, about 80%, about 85%, about 90%, or about 95% of the thickness of the current collector 520, as measured from the surface of the current collector 520 adjacent to the reinforcing layer 530, including all values and ranges therebetween. In some embodiments, the intersection between protrusions 511 of electrode material 510 and protrusions 531 of reinforcing layer 530 may be substantially uniform across all apertures 520. In some embodiments, the intersection between the protrusions 511 of the electrode material 510 and the protrusions 531 of the reinforcing layer 530 may be non-uniform.

In some embodiments, electrode material 510 may be coated onto current collector 520, and protrusions 511 may be created via portions of electrode material 510 that move or flow into apertures 522. In some embodiments, the electrode material 510 may include one or more binders. In some embodiments, the electrode material 510 may be binder-free or substantially binder-free. In some embodiments, electrode material 510 may be pressed onto current collector 520 to press portions of electrode material 510 into holes 522, thereby creating protrusions 511. In some embodiments, the electrode material 510 may comprise a semi-solid electrode material. In some embodiments, electrode material 510 may be deposited onto the current collector via electrochemical deposition, vapor deposition, sputtering, or any other suitable deposition method. In some embodiments, the electrode material 510 may comprise a high capacity material. In some embodiments, the high capacity material may comprise tin, silicon, antimony, aluminum, and/or titanium oxide. In some embodiments, the High capacity material may comprise any of the High capacity materials described in U.S. patent publication No. 2019/0363351 entitled "High Energy density component gradient electrode and method of making same (High Energy-Density Composition-Gradient Electrodes and Methods of Making the Same)" filed on 5/24, the disclosure of which is hereby incorporated by reference in its entirety.

Fig. 6 is an illustration of an electrode 600 having a current collector enhancement system according to one embodiment. As shown, electrode 600 includes electrode material 610 and lithium-containing layer 650 disposed on a first side of current collector 620 and reinforcing layer 630 disposed on a second side of current collector 620, the second side being opposite the first side. A film material 640 is disposed on the reinforcement layer 630. In some embodiments, electrode material 610, current collector 620, reinforcing layer 630, and membrane material 640 may be the same or substantially similar to electrode material 110, current collector 120, reinforcing layer 130, and membrane material 140, respectively, as described above with reference to fig. 1. Accordingly, certain aspects of the electrode material 610, the current collector 620, the reinforcing layer 630, and the film material 640 are not described in greater detail herein.

In some embodiments, a lithium-containing layer 650 may be disposed in the electrode 600 for prelithiation. Systems and methods of prelithiation are described in U.S. patent No. 10,497,935 (hereinafter, "the' 935 patent"), entitled, "prelithiation of Electrode materials in semi-Solid electrodes," filed on day 2015, 11, 3, the entire disclosure of which is hereby incorporated by reference. In some embodiments, the active material loading in the lithium-containing layer 650 may be lower than the active material loading in the electrode material 610.

Fig. 7A-7B are illustrations of an electrode 700 with a current collector enhancement system according to one embodiment. Fig. 7A shows a cross-sectional view of the electrode 700, while fig. 7B shows an exploded view of the components of the electrode 700. As shown, electrode 700 includes electrode material 710 disposed on a first side of current collector 720 and a high capacity coating 760 between electrode material 710 and current collector 720. A film material 740 is disposed on a second side of the current collector 720. The current collector 720 includes holes 722, and the electrode material 710 includes protrusions 711 penetrating the holes 722. In some embodiments, electrode material 710, protrusion 711, current collector 720, aperture 722, and film material 740 may be the same or substantially similar to electrode material 510, protrusion 511, current collector 520, aperture 522, and film material 540, as described above with reference to fig. 5A-5B. Accordingly, certain aspects of the electrode material 710, the protrusions 711, the current collectors 720, the apertures 722, and the membrane material 740 are not described in greater detail herein.

In some embodiments, the electrode material 710 may comprise a semi-solid anode material. In some embodiments, the electrode material 710 may comprise a semi-solid cathode material. In some embodiments, electrode material 710 is a graphite-containing semi-solid anode material. In some embodiments, the electrode material 710 may comprise a graphite-silicon slurry.

As shown, current collector 720 has an increased thickness compared to a standard current collector. Further, the current collector 720 is a mesh-shaped current collector having holes 722. The thickness of the current collector 720 and the hole 722 together may prevent distortion of the current collector 720. In other words, the thickness of the current collector 720 may help prevent the current collector 720 from bending, while the holes 722 allow for dispersion of internal stresses. In some embodiments, the current collector 720 may be composed of an alloy. In some embodiments, the current collector 720 may comprise a copper alloy. In some embodiments, the current collector 720 may be a beryllium copper current collector.

In some embodiments, the current collector 720 can have a thickness of at least about 20 μm, at least about 21 μm, at least about 22 μm, at least about 23 μm, at least about 24 μm, at least about 25 μm, at least about 26 μm, at least about 28 μm, at least about 30 μm, at least about 32 μm, at least about 34 μm, at least about 35 μm, at least about 36 μm, at least about 38 μm, at least about 40 μm, at least about 42 μm, at least about 44 μm, at least about 45 μm, at least about 46 μm, at least about 48 μm, at least about 50 μm, at least about 52 μm, at least about 54 μm, at least about 55 μm, at least about 56 μm, or at least about 58 μm. In some embodiments, the current collector 720 can have a thickness of no more than about 60 μm, no more than about 58 μm, no more than about 56 μm, no more than about 55 μm, no more than about 54 μm, no more than about 52 μm, no more than about 50 μm, no more than about 48 μm, no more than about 46 μm, no more than about 45 μm, no more than about 44 μm, no more than about 42 μm, no more than about 40 μm, no more than about 38 μm, no more than about 36 μm, no more than about 35 μm, no more than about 34 μm, no more than about 32 μm, no more than about 30 μm, no more than about 28 μm, no more than about 26 μm, no more than about 25, no more than about 24, no more than about 23, no more than about 22, or no more than about 21. Combinations of the above thicknesses of the current collector 720 are also possible (e.g., at least about 20 μm and no more than about 60 μm or at least about 40 μm and no more than about 50 μm), including all values and ranges therebetween. In some embodiments, the current collector 720 may have a thickness of about 20 μm, about 21 μm, about 22 μm, about 23 μm, about 24 μm, about 25 μm, about 26 μm, about 28 μm, about 30 μm, about 32 μm, about 34 μm, about 35 μm, about 36 μm, about 38 μm, about 40 μm, about 42 μm, about 44 μm, about 45 μm, about 46 μm, about 48 μm, about 50 μm, about 52 μm, about 54 μm, about 55 μm, about 56 μm, about 58 μm, or about 60 μm.

In some embodiments, the current collector 720 may have a porosity of at least about 10%, at least about 15%, at least about 20%, at least about 25%, at least about 30%, at least about 35%, at least about 40%, at least about 45%, at least about 50%, at least about 55%, at least about 60%, at least about 65%, at least about 70%, at least about 75%, at least about 80%, or at least about 85%. In some embodiments, current collector 720 may have a porosity of no more than about 90%, no more than about 85%, no more than about 80%, no more than about 75%, no more than about 70%, no more than about 65%, no more than about 60%, no more than about 55%, no more than about 50%, no more than about 45%, no more than about 40%, no more than about 35%, no more than about 30%, no more than about 25%, no more than about 20%, or no more than about 15%. Combinations of the above-described porosity values of the current collector 720 are also possible (e.g., at least about 10% and no more than about 90% or at least about 70% and no more than about 80%), including all values and ranges therebetween. In some embodiments, the current collector 720 may have a porosity of about 10%, about 15%, about 20%, about 25%, about 30%, about 35%, about 40%, about 45%, about 50%, about 55%, about 60%, about 65%, about 70%, about 75%, about 80%, about 85%, or about 90%.

In some embodiments, electrode 700 may be an anode and current collector 720 may be an anode current collector. In some embodiments, the anode current collector may be composed of copper, nickel, stainless steel, titanium, nickel-plated iron, conductive nonmetallic materials, carbon nanofibers, or any other suitable material or combination thereof. In some embodiments, electrode 700 may be a cathode current collector. In some embodiments, the cathode current collector may comprise aluminum, stainless steel, gold plated iron, platinum plated iron, or any other suitable material or combination thereof.

A high capacity coating 760 is applied to the current collector 720. As shown, the high capacity coating 760 includes holes 762. In some embodiments, the high capacity coating 760 may have a mesh pattern similar to the current collector 720. In some embodiments, the high-capacity coating 760 can comprise silicon, and the inclusion of the high-capacity coating 760 can be effective to render the electrode 700 a multi-layered electrode.

In some embodiments, the high capacity coating 760 can have a thickness of at least about 500nm, at least about 600nm, at least about 700nm, at least about 800nm, at least about 900nm, at least about 1 μm, at least about 1.5 μm, at least about 2 μm, at least about 2.5 μm, at least about 3 μm, at least about 4 μm, at least about 5 μm, at least about 6 μm, at least about 7 μm, at least about 8 μm, at least about 9 μm, at least about 10 μm, at least about 11 μm, at least about 12 μm, at least about 13 μm, at least about 14 μm, at least about 15 μm, at least about 16 μm, at least about 17 μm, at least about 18 μm, at least about 19 μm, at least about 20 μm, at least about 21 μm, at least about 22 μm, at least about 23 μm, at least about 24 μm, at least about 25 μm, at least about 30 μm, at least about 35 μm, at least about 40 μm, at least about 45 μm, at least about 50 μm, at least about 55 μm, at least about 60 μm, at least about 75 μm, or at least about 75 μm. In some embodiments, the high capacity coating 760 can have a thickness of no more than about 80 μm, no more than about 75 μm, no more than about 70 μm, no more than about 65 μm, no more than about 60 μm, no more than about 55 μm, no more than about 50 μm, no more than about 45 μm, no more than about 40 μm, no more than about 35 μm, no more than about 30 μm, no more than about 25 μm, no more than about 24 μm, no more than about 23 μm, no more than about 22 μm, no more than about 21 μm, no more than about 20 μm, no more than about 19 μm, no more than about 18 μm, no more than about 17 μm, no more than about 16 μm, no more than about 15 μm, no more than about 14 μm, no more than about 13 μm, no more than about 12 μm, no more than about 11 μm, no more than about 10 μm, no more than about 9 μm, no more than about 8 μm, no more than about 7 μm, no more than about 6 μm, no more than about 5 μm, no more than about 4 μm, no more than about 3 nm, no more than about 600nm, no more than about 2 nm, no more than about 1 nm, no more than about 600 nm.

Combinations of the above thickness values for the high-capacity coating 760 are also possible (e.g., at least about 500nm and no more than about 80 μm or at least about 5 μm and no more than about 15 μm, including all values and ranges therebetween. In some embodiments, the high-capacity coating 760 can have a thickness of about 500nm, about 600nm, about 700nm, about 800nm, about 900nm, about 1 μm, about 1.5 μm, about 2 μm, about 2.5 μm, about 3 μm, about 4 μm, about 5 μm, about 6 μm, about 7 μm, about 8 μm, about 9 μm, about 10 μm, about 11 μm, about 12 μm, about 13 μm, about 14 μm, about 15 μm, about 16 μm, about 17 μm, about 18 μm, about 19 μm, about 20 μm, about 21 μm, about 22 μm, about 23 μm, about 24 μm, about 25 μm, about 30 μm, about 35 μm, about 40 μm, about 45 μm, about 60 μm, about 75 μm, about 50 μm, about 75 μm, or about 50 μm).

In some embodiments, the high capacity coating 760 may be applied to the current collector 720 via a dry coating process. In some embodiments, the dry coating method may comprise sputtering, plasma, cold spray, electrochemical coating, or any other suitable coating method or combination thereof. In some embodiments, the high capacity coating 760 may be applied to the current collector 720 without the use of a binder. In some embodiments, the high capacity coating 760 may be applied to the current collector 720 via a wet coating process. In some embodiments, wet coating may be performed via dip coating, spray coating, gravure coating, or any other suitable coating method or combination thereof. In some embodiments, the wet coating method may comprise a binder.

Fig. 8A-8B are illustrations of an electrode 800 having a current collector enhancement system according to one embodiment. Fig. 8A shows a cross-sectional view of electrode 800, while fig. 8B shows an exploded view of the components of electrode 800. As shown, electrode 800 is a double sided electrode. As shown, electrode 800 includes electrode materials 810a, 810b including protrusions 811, electrode materials 810a, 810b disposed on a current collector 820 having holes 822, and high capacity materials 860a, 860b having holes 862a, 862 b. In some embodiments, electrode material 810a, 810B, protrusion 811, current collector 820, aperture 822, high capacity material 860a, 860B, and apertures 862a, 862B may be the same or substantially similar to electrode material 710, protrusion 711, current collector 720, aperture 722, high capacity material 760, and aperture 762, as described above with reference to fig. 7A-7B. Accordingly, certain aspects of the electrode materials 810a, 810b, the protrusion 811, the current collector 820, the aperture 822, the high capacity materials 860a, 860b, and the apertures 862a, 862b are not described in greater detail herein.

In some embodiments, the electrode 800 may be incorporated into a bicell. In some embodiments, electrode material 810a may be the same as or substantially similar to electrode material 810 b. In some embodiments, the high capacity material 860a may be the same as or substantially similar to the high capacity material 860b.

Fig. 9 is an illustration of an electrochemical cell 900 with a current collector enhancement system according to one embodiment. As shown, the electrochemical cell 900 is a bicell. Electrochemical cell 900 includes anode materials 910a, 910b including protrusions 911, anode materials 910a, 910b disposed on anode current collector 920 having holes 922, high capacity materials 960a, 960b having holes 962a, 962b, and membrane materials 970a, 970b. Cathode materials 930a, 930b are disposed on cathode current collectors 940a, 940b, respectively, with separator 950a disposed between anode material 910a and cathode material 930a, and separator 950b disposed between anode material 910b and cathode material 930 b. In some embodiments, anode material 910a, 910B, protrusion 911, anode current collector 920, aperture 922, high capacity material 960a, 960B, and apertures 962a, 962B may be the same as or substantially similar to electrode material 810, protrusion 811, current collector 820, aperture 822, high capacity material 860, and aperture 862, as described above with reference to fig. 8A-8B. In some embodiments, the membrane materials 970a, 970B can be the same or substantially similar as the membrane material 740, as described above with reference to fig. 7A-7B. Thus, certain aspects of anode materials 910a, 910b, protrusions 911, anode current collector 920, aperture 922, high capacity materials 960a, 960b, apertures 962a, 962b, and membrane materials 970a, 970b are not described in greater detail herein.

As shown, the electrochemical cell 900 is oriented with the anode materials 910a, 910b adjacent to a single anode current collector 920 and the cathode materials 930a, 930b located near the outside of the electrochemical cell 900. In some embodiments, the cathode materials 930a, 930b may be positioned adjacent to the central current collector while the anode materials 910a, 910b are positioned near the outside of the electrochemical cell 900. In some embodiments, the electrochemical cell 900 may have any of the properties of the electrochemical cell described in U.S. patent publication No. 2021/0249995 ("the' 695 publication"), entitled "split energy electrochemical cell and method of producing same (Divided Energy Electrochemical Cells and Methods of Producing the Same)" filed on day 2 of 2021, the entire disclosure of which is hereby incorporated by reference. In some embodiments, electrochemical cell 900 may have any of the properties of the electrochemical cell described in U.S. patent No. 10,637,038 ("the' 038 patent"), entitled "electrochemical cell with semi-solid electrode and method of making same (Electrochemical Cells Having Semi-Solid Electrodes and Methods of Manufacturing the same)", filed on 11/4/2015, the entire disclosure of which is hereby incorporated by reference.

Fig. 10 is a block diagram of a method 10 of producing an electrode with a current collector enhancement system. As shown, the method 10 optionally includes perforating the current collector at step 11. The method 10 further includes applying a reinforcing layer to a first side of the current collector at step 12 and laminating the reinforcement to the current collector at step 13. The method 10 optionally includes applying a lithium-containing layer at step 14. The method further comprises applying an electrode material at step 15. At step 16, the method 10 optionally includes applying a film to the reinforcing layer.

Perforating the current collector of step 11 may comprise punching, punching holes, drilling holes, nailing holes or any other suitable perforation method or combination thereof. Any number of holes may be perforated in the current collector. In some embodiments, a single apparatus with multiple piercing devices may be employed to pierce the current collector. In some embodiments, a single device may pierce the current collector multiple times. In some embodiments, the apparatus or the piercing device may comprise a needle. In some embodiments, holes may be machined in the current collector during the manufacturing process. In other words, the current collector may be manufactured with holes designed in the current collector. In some embodiments, the portion of the current collector material removed from the current collector to form the pores may be recovered.

In step 12, a reinforcing layer is applied to the current collector. In some embodiments, the reinforcing layer may be laminated to the current collector. In some embodiments, the reinforcing layer may be applied to the same side of the current collector as the perforation device perforates to form the holes. In some embodiments, the reinforcing layer may be applied to the current collector on the side opposite the side where the perforation device perforates to form the holes. In some embodiments, the reinforcing layer may include a binder and/or adhesive to facilitate adhesion to the current collector.

In step 13, the reinforcement is laminated to the current collector. In some embodiments, the extrusion of the reinforcing layer may be sufficient to at least partially push the reinforcing layer through the pores on the current collector. In step 14, a lithium-containing layer is optionally added. In some embodiments, the lithium-containing layer is applied to a current collector. In some embodiments, the lithium-containing layer is applied to an electrode material.

In step 15, electrode material is added. In some embodiments, the electrode material may be applied to a current collector. In some embodiments, the electrode material may be pressed onto a current collector. In some embodiments, pressing the electrode material onto the current collector may compress the electrode material into the pores on the current collector. In some embodiments, the electrode material may be applied to the lithium-containing layer. Step 16 comprises optionally applying a film material to the reinforcing layer. The membrane material may further strengthen the reinforcement material. In some embodiments, the film material may be combined with another film material to form a pouch. After an electrode has been formed, the electrode may be coupled to another electrode with a separator disposed therebetween to form an electrochemical cell.

Various concepts may be embodied as one or more methods, at least one example of which has been provided. Acts performed as part of the method may be ordered in any suitable manner. Thus, embodiments may be constructed that perform the actions in a different order than illustrated, which may involve performing some actions simultaneously, even though shown as sequential in the illustrative embodiments. In other words, it should be understood that these features are not necessarily limited to a particular order of execution, but rather any number of threads, processes, services, servers, etc. that can execute in serial, asynchronous, concurrent, parallel, simultaneous, synchronous, etc. modes in a manner consistent with the present disclosure. Thus, some of these features may be mutually contradictory in that they cannot be present in a single embodiment at the same time. Similarly, some features are applicable to one aspect of the innovation, and not to the other.

Furthermore, the present disclosure may incorporate other innovations not presently described. The applicant reserves all rights to these innovations including the right to carry out these innovations, submit their additional applications, continue, partially continue, divide, etc. Thus, it should be understood that the advantages, embodiments, examples, functions, features, logic, operations, organization, structure, topology, and/or other aspects of the present disclosure should not be considered limitations of the present disclosure as defined by the embodiments or limitations of equivalents to the embodiments. Depending on the particular desires and/or characteristics of the individual and/or enterprise users, database configuration and/or relational model, data type, data transmission and/or network framework, grammatical structures, etc., various embodiments of the technology disclosed herein may be implemented in a manner that achieves a great deal of flexibility and customization described herein.

It will be understood that all definitions, as defined and used herein, take precedence over dictionary definitions, definitions in documents incorporated by reference, and/or ordinary meanings of the defined terms.

As used herein, in particular embodiments, the term "about" or "approximately" when appearing before a numerical value indicates a range of ±10% of that value. Where a range of values is provided, it is understood that each intervening value, to the tenth of the unit of the lower limit unless the context clearly dictates otherwise, between the upper and lower limit of that range and any other stated or intervening value in that stated range is encompassed within the disclosure. The upper and lower limits of these smaller ranges may independently be included in the smaller ranges, and are also encompassed within the disclosure, subject to any specifically excluded limit in the stated range. Where a specified range includes one or both of the limits, ranges excluding either or both of those included limits are also included in the disclosure.

The phrase "and/or" as used herein in the specification and embodiments should be understood to mean "either or both" of the elements so combined, i.e., elements that in some cases exist in combination and in other cases exist separately. The various elements listed as "and/or" should be interpreted in the same manner, i.e., "one or more" of the elements so combined. In addition to the elements specifically identified by the "and/or" clause, other elements may optionally be present, whether related or unrelated to those elements specifically identified. Thus, as a non-limiting example, a reference to "a and/or B" when used in conjunction with an open language such as "comprising" may refer in one embodiment to a alone (optionally containing elements other than B); in another embodiment only B (optionally containing elements other than a); in yet another embodiment refers to both a and B (optionally containing other elements); etc.

As used herein in the specification and embodiments, "or" should be understood to have the same meaning as "and/or" defined above. For example, when multiple items are separated in a list, "or" and/or "will be construed as inclusive, i.e., including at least one, but also including more than one, and optionally additional, unlisted items in the multiple elements or element list. Only terms explicitly indicated to the contrary, such as "only one of …" or "exactly one of …", or "consisting of …" as used in an embodiment, will refer to exactly one element of the plurality or list of elements. Generally speaking, when there are preceding exclusive terms (e.g., "any one of …," "one of …," "one of … only," or "one of … exactly," as used herein, the term "or" should be interpreted merely to indicate exclusive choice (i.e., "one or the other, but not two"). When used in an embodiment, "consisting essentially of …" should have the ordinary meaning used in the patent statutes.

As used herein in the specification and embodiments, the phrase "at least one" should be understood to mean at least one element selected from any one or more elements in the list of elements, but does not necessarily include at least one of each element specifically listed in the list of elements, and does not exclude any combination of elements in the list of elements. This definition also allows that elements other than the element referred to by the phrase "at least one" specifically identified within the list of elements may optionally be present, whether or not they relate to those elements specifically identified. Thus, as a non-limiting example, "at least one of a and B" (or equivalently, "at least one of a or B," or equivalently, "at least one of a and/or B") may refer to at least one, optionally comprising more than one, a, absent B (and optionally comprising elements other than B) in one embodiment; in another embodiment at least one, optionally comprising more than one B, in the absence of a (and optionally comprising an element other than a); in yet another embodiment at least one, optionally comprising more than one a, and at least one, optionally comprising more than one B (and optionally comprising other elements); etc.

In the claims and in the above description, all transitional phrases such as "comprising," "including," "carrying," "having," "containing," "involving," "containing," "consisting of …," and the like are to be understood to be open-ended, i.e., to mean including but not limited to. As described in section 2111.03 of the U.S. patent office patent review program manual, only the transitional phrases "consisting of …" and "consisting essentially of …" are closed or semi-closed transitional phrases, respectively.

While particular embodiments of the present disclosure have been outlined above, many alternatives, modifications, and variations will be apparent to those skilled in the art. Accordingly, the embodiments described herein are intended to be illustrative rather than limiting. Various changes may be made without departing from the spirit and scope of the disclosure. In the event that the above-described methods and steps indicate certain events occurring in a certain order, those of ordinary skill in the art having the benefit of this disclosure will recognize that the order of certain steps may be modified and that such modifications are in accordance with the variations of the invention. In addition, certain steps may be performed in parallel, where possible, or may be performed sequentially as described above. The embodiments have been particularly shown and described, but it will be understood that various changes in form and detail may be made.

Claims

1. An electrode, comprising:

a current collector;

an electrode material disposed on a first side of the current collector; and

and a reinforcing layer disposed on the second side of the current collector, the reinforcing layer having a modulus of elasticity greater than a modulus of elasticity of the current collector.

2. The electrode of claim 1, further comprising:

a polymer film disposed on a first side of the reinforcing layer opposite a second surface of the reinforcing layer, the second side of the reinforcing layer coupled with the first side of the current collector.

3. The electrode of claim 1, wherein the electrode comprises a polymeric binder disposed between the reinforcing layer and the current collector.

4. The electrode of claim 3, wherein the polymeric binder comprises at least one elastomer or crosslinked polymer.

5. The electrode of claim 1, wherein the current collector comprises a plurality of pores.

6. The electrode of claim 1, wherein the reinforcement layer comprises at least one of sodium silicate, ceramic powder, glass fiber, carbon nanotube, carbon nanofiber, or carbon fiber.

7. The electrode of claim 1, wherein the reinforcing layer has a modulus of elasticity sufficient to reduce the amount of stretching and mechanical stress on the current collector that occurs during operation of the electrode.

8. The electrode of claim 1, wherein the enhancement layer has a thickness of less than about 10 μιη.

9. The electrode of claim 1, wherein the electrode material is a semi-solid electrode material comprising an active material and a conductive material in a liquid electrolyte.

10. The electrode of claim 1, wherein the electrode material is an anode material, the electrode further comprising a lithium-containing layer disposed between the current collector and the anode material.

11. An electrode, comprising:

a current collector having a plurality of holes;

an electrode material disposed on a first side of the current collector; and

a reinforcing layer disposed on a second side of the current collector such that the reinforcing layer at least partially fills void volumes created by the plurality of pores in the current collector to form a reinforced current collector,

the reinforcing layer has an elastic modulus greater than that of the current collector.

12. The electrode of claim 11, further comprising:

a polymer film disposed on a first side of the reinforcement layer opposite a second side of the reinforcement layer coupled with the first side of the current collector.

13. The electrode of claim 11, wherein the electrode comprises a polymeric binder disposed between the reinforcing layer and the current collector.

14. The electrode of claim 11, wherein the material for reinforcement layer completely fills the void volume created by the plurality of pores such that the reinforcement material physically contacts the electrode material.

15. The electrode of claim 11, wherein the reinforcement layer comprises at least one of sodium silicate, ceramic powder, glass fiber, carbon nanotube, carbon nanofiber, or carbon fiber.

16. The electrode of claim 11, wherein the enhanced current collector reduces tensile or mechanical stress during electrode operation as compared to an uncoated current collector.

17. The electrode of claim 11, wherein the enhancement layer has a thickness of less than about 10 μιη.

18. The electrode of claim 11, wherein the electrode material is a semi-solid electrode material comprising an active material and a conductive material in a liquid electrolyte.

19. The electrode of claim 11, wherein the electrode material is an anode material, the electrode further comprising a lithium-containing layer disposed between the current collector and the anode material.

20. A method of forming an electrode:

applying a reinforcing layer to a first side of a current collector, the reinforcing layer having a modulus of elasticity greater than a modulus of elasticity of the current collector;

laminating the reinforcement to the current collector to form a reinforced current collector; and

electrode material is applied to the second side of the current collector.

21. The method as recited in claim 20, further comprising:

a lithium-containing layer is applied to the second side of the current collector prior to application of the electrode material.

22. The method as recited in claim 20, further comprising:

a polymer film is applied to a first side of the reinforcing layer opposite a second side of the reinforcing layer coupled with the first side of the current collector.

23. The method as recited in claim 20, further comprising:

the current collector is pierced to create a plurality of holes prior to applying the reinforcing layer to the current collector.

24. The method as recited in claim 23, further comprising:

the plurality of pores in the current collector are at least partially filled with the reinforcing layer.

25. The method as recited in claim 24, further comprising:

the plurality of pores in the current collector are at least partially filled with the electrode material such that there is physical contact between the electrode material and the reinforcing layer.

26. The method as recited in claim 20, further comprising:

a polymeric binder is disposed between the current collector and the reinforcing layer.