ULTRA-HIGH POWER HYBRID CELL DESIGN WITH UNIFORM THERMAL DISTRIBUTION

A capacitor-assisted hybrid lithium-ion electrochemical cell assembly includes two positive electrodes having a first polarity, each having at least two electrically conductive tabs disposed on at least one first edge and at least one second edge. Further, two negative electrodes having a second polarity each having at least two electrically conductive tabs disposed on at least one first edge and at least one second edge. At least one of the two positive electrodes or negative electrodes are distinct from one another. The electrically conductive tabs are substantially aligned in the electrochemical cell to respectively define a plurality of positive electrical connectors and a plurality of negative electrical connectors to reduce current density during high power charging and discharging.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit and priority of Chinese Patent Application No. 201910977475.9, filed Oct. 15, 2019. The entire disclosure of the above application is incorporated herein by reference.

INTRODUCTION

The present disclosure relates to hybrid lithium-ion electrochemical cells having high-energy capacity and high power capacity. Such, capacitor-assisted hybrid lithium-ion electrochemical cells include an assembly of electrodes each having a plurality of conductive tabs on distinct edges that form positive and negative electrical connectors on multiple edges of the capacitor-assisted lithium-ion electrochemical cell to reduce current density and improve thermal management.

High-energy density electrochemical cells, such as lithium-ion batteries can be used in a variety of consumer products and vehicles, such as hybrid or electric vehicles. Typical lithium-ion batteries comprise at least one positive electrode or cathode, at least one negative electrode or an anode, an electrolyte material, and a separator. A stack of lithium-ion battery cells may be electrically connected in an electrochemical device to increase overall output. Lithium-ion batteries operate by reversibly passing lithium ions between the negative electrode and the positive electrode. A separator and an electrolyte are disposed between the negative and positive electrodes. The electrolyte is suitable for conducting lithium ions and may be in solid or liquid form. Lithium ions move from a cathode (positive electrode) to an anode (negative electrode) during charging of the battery, and in the opposite direction when discharging the battery. Each of the negative and positive electrodes within a stack is connected to a current collector (typically a metal, such as copper foil for the anode and aluminum foil for the cathode). During battery usage, the current collectors associated with the two electrodes are connected by an external circuit that allows current generated by electrons to pass between the electrodes to compensate for transport of lithium ions.

The potential difference or voltage of a battery cell is determined by differences in chemical potentials (e.g., Fermi energy levels) between the electrodes. Under normal operating conditions, the potential difference between the electrodes achieves a maximum achievable value when the battery cell is fully charged and a minimum achievable value when the battery cell is fully discharged. The battery cell will discharge and the minimum achievable value will be obtained when the electrodes are connected to a load performing the desired function (e.g., electric motor) via an external circuit. Each of the negative and positive electrodes in the battery cell is connected to a current collector (typically a metal, such as copper for the anode and aluminum for the cathode). The current collectors associated with the two electrodes are connected by an external circuit that allows current generated by electrons to pass between the electrodes to compensate for transport of lithium ions across the battery cell. For example, during cell discharge, the internal Li+ionic current from the negative electrode to the positive electrode may be compensated by the electronic current flowing through the external circuit from the negative electrode to the positive electrode of the battery cell.

Many different materials may be used to create components for a lithium ion battery. For example, positive electrode materials for lithium batteries typically comprise an electroactive material which can be intercalated or reacted with lithium ions, such as lithium-transition metal oxides or mixed oxides, for example including LiMn2O4, LiCoO2, LiNiO2, LiMn1.5Ni0.5O4, LiNi(1-x-y)CoxMyO2(where 0<x<1, y<1, and M may be Al, Mn, or the like), or one or more phosphate compounds, for example including lithium iron phosphate or mixed lithium manganese-iron phosphate. The negative electrode typically includes a lithium insertion material or an alloy host material. For example, typical electroactive materials for forming an anode include graphite and other forms of carbon, silicon and silicon oxide, lithium titanate (Li4Ti5O12), tin and tin alloys.

One approach to increase the power of lithium-ion electrochemical cells is to create systems that include electrodes with both a high energy capacity electroactive material and a high power capacity electroactive material (for example, a first positive electrode comprising a high energy capacity electroactive material and a second positive electrode comprising a high power capacity electroactive material). Energy capacity or density is an amount of energy the battery can store with respect to its mass (watt-hours per kilogram (Wh/kg)). Power capacity or density is an amount of power that can be generated by the battery with respect to its mass (watts per kilogram (W/kg)). These hybrid cells may be referred to as capacitor-assisted lithium-ion batteries. However, including high power capacity materials can result in higher charges and pose potential thermal management issues during charging and discharging of the electrochemical device. It would be advantageous to develop high power hybrid lithium-ion cells, which along with high power capacity and high energy capacity, also have uniform current density and good thermal distribution.

SUMMARY

In certain aspects, the present disclosure relates to a capacitor-assisted hybrid lithium-ion electrochemical cell assembly that includes a first positive electrode having a first polarity and at least two first electrically conductive tabs disposed on at least one first edge of the first positive electrode and at least one second edge distinct from the first edge. The capacitor-assisted hybrid lithium-ion electrochemical cell assembly also include a second positive electrode having the first polarity and at least two second electrically conductive tabs disposed on at least one first edge of the second positive electrode and at least one second edge distinct from the first edge. A third negative electrode having a second polarity opposite to the first polarity is also included having at least two third electrically conductive tabs disposed on at least one first edge of the third negative electrode and at least one second edge distinct from the first edge. A fourth negative electrode having the second polarity and at least two fourth electrically conductive tabs is disposed on at least one first edge of the fourth negative electrode and at least one second edge distinct from the first edge. In certain variations, the second positive electrode includes a distinct active material from the first positive electrode. In other variations, the fourth negative electrode includes a distinct active material from the third negative electrode. The at least two first electrically conductive tabs and the at least two second electrically conductive tabs are substantially aligned in the electrochemical cell assembly to respectively define a plurality of positive electrical connectors. Similarly, the at least two third electrically conductive tabs and the at least two fourth electrically conductive tabs are substantially aligned in the electrochemical cell assembly to define a plurality of negative electrical connectors spaced apart from the plurality of positive electrical connectors to reduce current density during high power charging and discharging.

In one aspect, the at least one first edge of the first positive electrode has a first length and the at least one second edge has a second length greater than the first length. Further, the at least one first edge of the second positive electrode has the first length and the at least one second edge has the second length. The at least one first edge of the third negative electrode has the first length and the at least one second edge has the second length. The at least one first edge of the fourth negative electrode has the first length and the at least one second edge has the second length. The first positive electrode, the second positive electrode, the third negative electrode, and the fourth negative electrode are assembled together to form the capacitor-assisted hybrid lithium-ion electrochemical cell assembly defining a first cell edge with the first length and a second cell edge with the second length. At least one of the plurality of positive electrical connectors and at least one of the negative electrical connectors is disposed on the first cell edge. Further, at least one of the plurality of positive electrical connectors and at least one of the negative electrical connectors is disposed on the second cell edge of the capacitor-assisted hybrid lithium-ion electrochemical cell assembly.

In one aspect, either the first positive electrode or third negative electrode includes a high energy capacity electroactive material. Further, the second positive electrode or the fourth negative electrode includes a high power capacity electroactive material. The first positive electrode and the third negative electrode define a lithium-ion battery. The second positive electrode and/or the fourth negative electrode define a capacitor.

In one aspect, the at least two first electrically conductive tabs include four first electrically conductive tabs disposed on each of four edges of the first positive electrode. The at least two second electrically conductive tabs include four second electrically conductive tabs disposed on each of four edges of the second positive electrode. The at least two third electrically conductive tabs include four third electrically conductive tabs disposed on each of four edges of the third negative electrode. The at least two fourth electrically conductive tabs include four fourth electrically conductive tabs disposed on each of four edges of the fourth negative electrode. The electrochemical cell assembly defines four cell edges that each include a positive electrical connector and a negative electrical connector.

In one aspect, the at least two first electrically conductive tabs include three first electrically conductive tabs disposed on each of three edges of the first positive electrode. The at least two second electrically conductive tabs include three second electrically conductive tabs disposed on each of three edges of the second positive electrode. The at least two third electrically conductive tabs include three third electrically conductive tabs disposed on each of three edges of the third negative electrode. The at least two fourth electrically conductive tabs include three fourth electrically conductive tabs disposed on each of three edges of the fourth negative electrode. The electrochemical cell assembly defines: (i) three cell edges including both a positive electrical connector and a negative electrical connector or (ii) a first cell edge having a positive electrical connector and a negative electrical connector, a second cell edge having a positive electrical connector and a negative electrical connector, a third cell edge having a positive electrical connector, and a fourth cell edge having a negative electrical connector.

In one aspect, the at least two first electrically conductive tabs include three electrically conductive tabs disposed on three edges of the first positive electrode and the at least two second electrically conductive tabs include three electrically conductive tabs disposed on three edges of the second positive electrode.

In one aspect, the at least two third electrically conductive tabs include three electrically conductive tabs disposed on three edges of the third negative electrode. The at least two fourth electrically conductive tabs include three electrically conductive tabs disposed on three edges of the third negative electrode.

In one aspect, a maximum current density is less than or equal to about 300 mA/cm2for at least one of the first electrode, the second electrode, the third electrode, or the fourth electrode.

In one aspect, the first positive electrode includes a first electroactive material selected from the group consisting of: LiNiMnCoO2, Li(NixMnyCoz)O2), where 0≤x≤1, 0≤y≤1, 0≤z≤1, and x+y+z=1, LiNiCoAlO2, LiNi1-x-yCoxAlyO2(where 0≤x≤1 and 0≤y≤1), LiNixMn1-xO2(where 0≤x≤1), LiMn2O4, Li1+xMO2(where M is one of Mn, Ni, Co, Al and 0≤x≤1), LiMn2O4(LMO), LiNixMn1.5O4, LiV2(PO4)3, LiFeSiO4, LiMPO4(where M is at least one of Fe, Ni, Co, and Mn), activated carbon, and combinations thereof.

In one aspect, the second positive electrode includes a second electroactive material and the fourth negative electrode includes a fourth electroactive material. At least one of the second electroactive material and/or the fourth electroactive material is selected from the group consisting of: silicon oxide, activated carbon, hard carbon, soft carbon, porous carbon materials, graphite, graphene, carbon nanotubes, carbon xerogels, mesoporous carbons, templated carbons, carbide-derived carbons (CDCs), graphene, porous carbon spheres, heteroatom-doped carbon materials, metal oxides of noble metals, RuO2, transition metals, hydroxides of transition metals, MnO2, NiO, Co3O4, Co(OH)2, Ni(OH)2, polyaniline (PANI), polypyrrole (PPy), polythiophene (PTh), and combinations thereof.

In one aspect, the third negative electrode includes a third negative electrode material selected from the group consisting of: lithium metal, lithium alloy, silicon (Si), silicon alloy, silicon oxide, hard carbon, soft carbon, graphite, graphene, carbon nanotubes, lithium titanium oxide (Li4Ti5O12), tin (Sn), vanadium oxide (V2O5), titanium dioxide (TiO2), titanium niobium oxide (TixNbyOzwhere 0≤x≤2, 0≤y≤24, and 0≤z≤64), ferrous sulfide (FeS), and combinations thereof.

In one aspect, each of the first positive electrode, the second positive electrode, the third negative electrode and the fourth negative electrode respectively includes a current collector having an electroactive layer disposed thereon. A portion of the current collector defines the plurality of electrically conductive tabs.

In one aspect, the electrochemical cell assembly includes at least three positive electrical connectors and at least three negative electrical connectors.

In certain other aspects, the present disclosure relates to a capacitor-assisted hybrid lithium-ion electrochemical cell assembly that includes a first positive electrode having a first polarity and at least two first electrically conductive tabs disposed on at least one first edge and at least one a second adjoining edge. A second positive electrode having the first polarity is also included having a distinct active material from the first positive electrode, and at least two second electrically conductive tabs disposed on at least one first edge and at least one second adjoining edge. A third negative electrode is also included having a second polarity opposite to the first polarity and at least two third electrically conductive tabs disposed on at least one first edge and at least one second adjoining edge. A fourth negative electrode having the second polarity and at least two fourth electrically conductive tabs disposed on at least one first edge and at least one second adjoining edge is also provided. The at least two first electrically conductive tabs and the at least two second electrically conductive tabs are substantially aligned in the electrochemical cell assembly to respectively define a plurality of positive electrical connectors. Further, the at least two third electrically conductive tabs and the at least two fourth electrically conductive tabs are substantially aligned in the electrochemical cell assembly to define a plurality of negative electrical connectors spaced apart from the plurality of positive electrical connectors to reduce current density during high power charging and discharging.

In one aspect, either the first positive electrode or third negative electrode includes a high energy capacity electroactive material. The second positive electrode or the fourth negative electrode includes a high power capacity electroactive material. The first positive electrode or and the third negative electrode define a lithium-ion battery and the second positive electrode and/or the fourth negative electrode define a capacitor.

In one aspect, at least two first electrically conductive tabs include three electrically conductive tabs disposed on three edges of the first positive electrode. The at least two second electrically conductive tabs include three electrically conductive tabs disposed on three edges of the second positive electrode.

In one aspect, the at least two third electrically conductive tabs include three electrically conductive tabs disposed on three edges of the third negative electrode. The at least two fourth electrically conductive tabs include three electrically conductive tabs disposed on three edges of the third negative electrode.

In one aspect, the first positive electrode includes a first electroactive material selected from the group consisting of: LiNiMnCoO2, Li(NixMnyCoz)O2), where 0≤x≤1, 0≤y≤1, 0≤z≤1, and x+y+z=1, LiNiCoAlO2, LiNi1-x-yCoxAlyO2(where 0≤x≤1 and 0≤y≤1), LiNixMn1-xO2(where 0≤x≤1), LiMn2O4, Li1+xMO2(where M is one of Mn, Ni, Co, Al and 0≤x≤1), LiMn2O4(LMO), LiNixMn1.5O4, LiV2(PO4)3, LiFeSiO4, LiMPO4(where M is at least one of Fe, Ni, Co, and Mn), activated carbon, and combinations thereof. The third negative electrode includes a third negative electrode material selected from the group consisting of: lithium metal, lithium alloy, silicon (Si), silicon alloy, silicon oxide, activated carbon, hard carbon, soft carbon, graphite, graphene, carbon nanotubes, lithium titanium oxide (Li4Ti5O12), tin (Sn), vanadium oxide (V2O5), titanium dioxide (TiO2), titanium niobium oxide (TixNbyOzwhere 0≤x≤2, 0≤y≤24, and 0≤z≤64), ferrous sulfide (FeS), and combinations thereof. The second positive electrode includes a second electroactive material and the fourth negative electrode includes a fourth electroactive material, wherein at least one of the second electroactive material and/or the fourth electroactive material is selected from the group consisting of: silicon oxide, activated carbon, hard carbon, soft carbon, porous carbon materials, graphite, graphene, carbon nanotubes, carbon xerogels, mesoporous carbons, templated carbons, carbide-derived carbons (CDCs), graphene, porous carbon spheres, heteroatom-doped carbon materials, metal oxides of noble metals, RuO2, transition metals, hydroxides of transition metals, MnO2, NiO, Co3O4, Co(OH)2, Ni(OH)2, polyaniline (PANI), polypyrrole (PPy), polythiophene (PTh), and combinations thereof.

In yet other aspects, the present disclosure relates to a capacitor-assisted hybrid lithium-ion electrochemical cell assembly. The assembly includes a first positive electrode having a first polarity and at least two first electrically conductive tabs disposed on at least one first edge of the first positive electrode and at least one second edge distinct from the first edge. A second positive electrode having the first polarity is provided with at least two second electrically conductive tabs disposed on at least one first edge of the second positive electrode and at least one second edge distinct from the first edge. Also included is a third negative electrode having a second polarity opposite to the first polarity and at least two third electrically conductive tabs disposed on at least one first edge of the third negative electrode and at least one second edge distinct from the first edge. A fourth negative electrode has the second polarity and at least two fourth electrically conductive tabs disposed on at least one first edge of the fourth negative electrode and at least one second edge distinct from the first edge. Either the first positive electrode or third negative electrode includes a high energy capacity electroactive material and the second positive electrode or the fourth negative electrode includes a high power capacity electroactive material. The at least two first electrically conductive tabs and the at least two second electrically conductive tabs are substantially aligned in the electrochemical cell assembly to respectively define at least one positive electrical connector. The at least two third electrically conductive tabs and the at least two fourth electrically conductive tabs are substantially aligned in the electrochemical cell assembly to define at least one negative electrical connector to reduce current density during high power charging and discharging.

In one aspect, the electrochemical cell assembly has at least one cell edge including both a positive electrical connector and spaced apart negative electrical connector.

DETAILED DESCRIPTION

One approach to increase the power of lithium-ion electrochemical cells is to create systems that include electrodes with both a high energy capacity electroactive material and a high power capacity electroactive material (for example, a first positive electrode comprising a high energy capacity electroactive material and a second positive electrode comprising a high power capacity electroactive material). Energy capacity or density is an amount of energy the battery can store with respect to its mass (watt-hours per kilogram (Wh/kg)). Power capacity or density is an amount of power that can be generated by the battery with respect to its mass (watts per kilogram (W/kg)). Such high power active materials are integrated into and can thus be used to create a capacitor within the lithium-ion electrochemical cell.

Thus, the present technology pertains to electrochemical cells including capacitors or hybrid supercapacitor-battery systems (e.g., capacitor-assisted batteries (“CAB”)), which integrate the high power density of capacitors with high energy density of lithium-ion batteries, that may be used in, for example, automotive or other vehicles (e.g., motorcycles, boats), but may also be used in a variety of other industries and applications, such as consumer electronic devices, by way of non-limiting example.

However, including high power capacity materials can result in higher charges and pose potential thermal management issues during charging and discharging of the electrochemical device. High power performance of Li-ion cells may be limited by current flow within electrodes, especially for hybrid capacitor-assisted battery designs that have instantaneously high power boost/regeneration. During high current charge or discharge, large temperature/thermal gradients can be observed. Increasing thermal gradients may lead to inconsistency ageing status of each electrode thus may affect cell durability.

A typical lithium-ion battery includes a first electrode (such as a positive electrode or cathode) opposing a second electrode (such as a negative electrode or anode) and a separator and/or electrolyte disposed therebetween. Often, in a lithium-ion battery pack, batteries or cells may be electrically connected (e.g., in a stack) to increase overall output. Lithium-ion batteries operate by reversibly passing lithium ions between the first and second electrodes. For example, lithium ions may move from a positive electrode to a negative electrode during charging of the battery, and in the opposite direction when discharging the battery. The electrolyte is suitable for conducting lithium ions and may be in liquid, gel, or solid form.

In hybrid capacitor-battery systems (e.g., capacitor-assisted batteries), a capacitor may be integrated with the lithium-ion battery or cell stack. A capacitor may include one or more capacitor components or layers, such as a positive electrode or cathode that can function as a capacitor in conjunction with a corresponding negative electrode or anode, that are parallel or stacked with the one or more electrodes that form the lithium-ion battery. The one or more capacitor components or layers may be integrated within a housing defining the lithium-ion battery or stack, such that a capacitor component is also in communication with the electrolyte of the lithium-ion battery. Each of the negative and positive electrodes and capacitor components within a hybrid battery pack or cell stack may be connected to a current collector (typically a metal, such as copper for the anode and/or capacitor-assisted anode and aluminum for the cathode and/or capacitor-assisted cathode). During battery usage, the current collectors associated with the (stacked) electrodes are connected by an external circuit that allows current generated by electrons to pass between the electrodes to compensate for transport of lithium ions.

By way of background,FIGS. 1A-1Bshow current distribution in a single high power lithium-ion pouch cell10like that described inElectrochimica Acta,133 pp. 197-208 (2014), the relevant portions of which are incorporated herein by reference. As can be seen, the current flows between a negative electrode tab12and a positive electrode tab14. As shown inFIG. 1B, a simplified lithium-ion battery is shown with planar electrodes that can be assembled together. The negative electrode tab12is electrically connected to an internal negative current collector16and negative electrode active layer18that together define a negative electrode. Likewise, the positive electrode tab14is electrically connected to an internal negative current collector20and positive electrode active layer22that together define a positive electrode. The positive and negative electrodes are electrically isolated from one another by a porous separator24. As can be seen, the current flow is generally concentrated in areas near the positive electrode tab14and negative electrode tab12. The arrows in the z-direction generally correspond to reaction current and transport of lithium ions (Li+) from the negative electrode to the positive electrode during a discharge process. The arrows in the x-y planes are current flowpath on the electrodes as current flowing from the negative electrode to the positive electrode during discharging.

FIG. 2shows thermal imaging of a lithium-ion pouch cell discharging at a 5 C rate in ambient air reproduced based on data from the Journal of the Electrochemical Society, 161 (14) pp. A2168-A2174 (2014), the relevant portions of which are incorporated herein by reference, showing high levels of heat generated near the positive electrode tab14. The y-axis is temperature ranging from 33° C. to 41° C. The C-rate is a rate at which a lithium-ion battery discharges relative to its maximum capacity, where a rate of 1 C is also known as a one-hour discharge and a discharge of 5 C is full discharge in about 12 minutes. As can be seen, uneven thermal distribution is observed during high power operations of the lithium-ion electrochemical cell, where under certain conditions, the positive electrode tab14electrical connector may be the hottest area. During high current charging or discharging, undesirable temperature/thermal gradients can be observed. As thermal gradients within the electrochemical cell increase, this may lead to inconsistent ageing of each electrode, which could affect cell durability. As such, high power performance of lithium-ion hybrid electrochemical cells is limited by thermal regulation and current flow within electrodes, especially for hybrid capacitor-assisted battery designs providing instantaneously high power boost and regeneration or recharging. As used herein, high power charging and discharging may be considered to be a charge or discharge rate of greater than or equal to 5 C to less than or equal to about 50 C for a period of greater than or equal to about 0.05 seconds to less than or equal to about 30 seconds.

FIG. 3shows an exemplary schematic illustration of a capacitor-assisted lithium-ion electrochemical cell (e.g. battery)30. The capacitor-assisted battery30includes at least two positive electrodes40,50and at least two negative electrodes60,70. The capacitor-assisted battery30may further includes an electrolyte100. A first positive electrode40may be parallel to a second positive electrode50and a negative electrode60may be disposed therebetween. A second negative electrode70may be parallel to a side or surface of the second positive electrode50that opposes the negative electrode60. Each of the electrodes40,50,60,70may have a porous separator80disposed therebetween to provide electrical separation between electrodes of opposite polarities. In designs with liquid electrolyte, the electrochemical cell30includes a separator structure. However, in certain solid electrolyte designs, no separator80may be necessary in the electrochemical cell, as the solid electrolyte may serve the role of both electrical insulator and ion conductor.

In certain aspects, as shown, the electrodes40,50,60,70may be disposed within a single battery housing110containing an electrolyte100. The skilled artisan will appreciate, however, that in various other aspects, other housing systems or designs may be present. For example, in certain variations, the first positive electrode40and the negative electrode60may be disposed within a first housing (e.g., a battery housing) having a first electrolyte, and the second positive electrode50and the second negative electrode70may be disposed within a second housing (e.g., capacitor housing) having a second electrolyte. In such instances, the first electrolyte may be the same or different from the second electrolyte.

In various aspects, the capacitor-assisted battery30may include greater than or equal to about 1 wt. % to less than or equal to about 25 wt. %, and in certain aspects, optionally greater than or equal to about 3 wt. % to less than or equal to about 20 wt. %, of the electrolyte100. Any appropriate electrolyte100, whether in solid, liquid, or gel form, capable of conducting lithium ions between the electrodes40,50,60,70may be used in the capacitor-assisted battery30. For example, the electrolyte100may be a non-aqueous liquid electrolyte solution that includes a lithium salt dissolved in an organic solvent or a mixture of organic solvents. Numerous conventional non-aqueous liquid electrolyte solutions may be employed in the capacitor-assisted battery30.

These and other similar lithium salts may be dissolved in a variety of organic solvents, including but not limited to various alkyl carbonates, such as cyclic carbonates (e.g., ethylene carbonate (EC), propylene carbonate (PC), butylene carbonate (BC), fluoroethylene carbonate (FEC)), linear carbonates (e.g., dimethyl carbonate (DMC), diethyl carbonate (DEC), ethyl methyl carbonate (EMC)), aliphatic carboxylic esters (e.g., methyl formate, methyl acetate, methyl propionate), γ-lactones (e.g., γ-butyrolactone, γ-valerolactone), chain structure ethers (e.g., 1,2-dimethoxyethane (DME), 1-2-diethoxyethane, ethoxymethoxyethane), cyclic ethers (e.g., tetrahydrofuran, 2-methyltetrahydrofuran), 1,3-dioxolane (DOL)), sulfur compounds (e.g., sulfolane), and combinations thereof. In various aspects, the electrolyte100may include greater than or equal to 1M to less than or equal to about 2M concentration of the one or more lithium salts. In certain variations, for example when the electrolyte has a lithium concentration greater than about 2 M or ionic liquids, the electrolyte100may include one or more diluters, such as fluoroethylene carbonate (FEC) and/or hydrofluoroether (HFE).

In various aspects, the electrolyte100may be a solid-state electrolyte including one or more solid-state electrolyte particles that may comprise one or more polymer-based particles, oxide-based particles, sulfide-based particles, halide-based particles, borate-based particles, nitride-based particles, and hydride-based particles. Such a solid-state electrolyte may be disposed in a plurality of layers so as to define a three-dimensional structure. In various aspects, the polymer-based particles may be intermingled with a lithium salt so as to act as a solid solvent.

In certain variations, the polymer-based particles may comprise one or more of polymer materials selected from the group consisting of: polyethylene glycol, poly(p-phenylene oxide) (PPO), poly(methyl methacrylate) (PMMA), polyacrylonitrile (PAN), polyvinylidene fluoride (PVDF), poly(vinylidene fluoride-co-hexafluoropropylene (PVDF-HFP), polyvinyl chloride (PVC), and combinations thereof. In one variation, the one or more polymer materials may have an ionic conductivity equal to about 10−4S/cm.

In various aspects, the oxide-based particles may comprise one or more garnet ceramics, LISICON-type oxides, NASICON-type oxides, and Perovskite type ceramics. For example, the one or more garnet ceramics may be selected from the group consisting of: Li6.5La3Zr1.75Te0.25O12, Li7La3Zr2O12, Li6.2Ga0.3La2.95Rb0.05Zr2O12, Li6.85La2.9Ca0.1Zr1.75Nb0.25O12, Li6.25Al0.25La3Zr2O12, Li6.75La3Zr1.75Nb0.25O12, Li6.75La3Zr1.75Nb0.25O12, and combinations thereof. The one or more LISICON-type oxides may be selected from the group consisting of: Li14Zn(GeO4)4, Li3+x(P1-xSix)O4(where 0≤x≤1), Li3+xGexV1-xO4(where 0≤x≤1), and combinations thereof. The one or more NASICON-type oxides may be defined by LiMM′(PO4)3, where M and M′ are independently selected from Al, Ge, Ti, Sn, Hf, Zr, and La. For example, in certain variations, the one or more NASICON-type oxides may be selected from the group consisting of: Li1+xAlxGe2-x(PO4)3(LAGP) (where 0≤x≤2), Li1+xAlxTi2-x(PO4)3(LATP) (where 0≤x≤2), Li1-xYxZr2-x(PO4)3(LYZP) (where 0≤x≤2), Li1.3Al0.3Ti1.7(PO4)3, LiTi2(PO4)3, LiGeTi(PO4)3, LiGe2(PO4)3, LiHf2(PO4)3, and combinations thereof. The one or more Perovskite-type ceramics may be selected from the group consisting of: Li3.3La0.53TiO3, LiSr1.65Zr1.3Ta1.7O9, Li2-x-ySr1-xTayZr1-yO3(where x=0.75y and 0.60≤y≤0.75), Li3/8Sr7/16Nb3/4Zr1/4O3, Li3xLa(2/3-x)TiO3(where 0<x<0.25), and combinations thereof. In one variation, the one or more oxide-based materials may have an ionic conductivity greater than or equal to about 10−5S/cm to less than or equal to about 10−3S/cm.

In various aspects, the sulfide-based particles may include one or more sulfide-based materials selected from the group consisting of: Li2S—P2S5, Li2S—P2S5-MSx(where M is Si, Ge, and Sn and 0≤x≤2), Li3.4Si0.4P0.6S4, Li10GeP2S11.7O0.3, Li9.6P3S12, Li9P3S9O3, Li10.35Si1.35P1.65S12, Li9.8Sn0.81P2.19S12, Li10(Si0.5Ge0.5)P2S12, Li(Ge0.5Sn0.5)P2S12, Li(Si0.5Sn0.5)PsS12, Li10GeP2S12(LGPS), Li6PS5X (where X is Cl, Br, or I), Li7P2S8I, Li10.35Ge1.35P1.65S12, Li3.25Ge0.25P0.75S4, Li10SnP2S12, Li10SiP2S12, Li9.54Si1.74P1.44Sn1.7Cl0.3, (1−x)P2S5-xLi2S (where 0.5≤x≤0.7), and combinations thereof. In one variation, the one or more sulfide-based materials may have an ionic conductivity greater than or equal to about 10−7S/cm to less than or equal to about 10−2S/cm.

In various aspects, the halide-based particles may include one or more halide-based materials selected from the group consisting of: Li2CdCl4, Li2MgCl4, Li2CdI4, Li2ZnI4, Li3OCl, LiI, Li5ZnI4, Li3OCl1-xBrx(where 0≤x≤1), and combinations thereof. In one variation, the one or more halide-based materials may have an ionic conductivity greater than or equal to about 10−8S/cm to less than or equal to about 10−5S/cm.

In various aspects, the borate-based particles may include one or more borate-based materials selected from the group consisting of: Li2B4O7, Li2O—(B2O3)—(P2O5), and combinations thereof. In one variation, the one or more borate-based materials may have an ionic conductivity greater than or equal to about 10−7S/cm to less than or equal to about 10−6S/cm.

In various aspects, the nitride-based particles may include one or more nitride-based materials selected from the group consisting of: Li3N, Li7PN4, LiSi2N3, LiPON, and combinations thereof. In one variation, the one or more nitride-based materials may have an ionic conductivity greater than or equal to about 10−9S/cm to less than or equal to about 10−3S/cm.

In various aspects, the hydride-based particles may include one or more hydride-based materials selected from the group consisting of: Li3AlH6, LiBH4, LiBH4—LiX (where X is one of Cl, Br, and I), LiNH2, Li2NH, LiBH4—LiNH2, and combinations thereof. In one variation, the one or more hydride-based materials may have an ionic conductivity greater than or equal to about 10−7S/cm to less than or equal to about 10−4S/cm.

In still further variations, the electrolyte100may be a quasi-solid electrolyte comprising a hybrid of the above detailed non-aqueous liquid electrolyte solution and solid-state electrolyte systems—for example including one or more ionic liquids and one or more metal oxide particles, such as aluminum oxide (Al2O3) and/or silicon dioxide (SiO2).

When the electrolyte100is a liquid, the porous separator80may include, in instances, a microporous polymeric separator including a polyolefin (including those made from a homopolymer (derived from a single monomer constituent) or a heteropolymer (derived from more than one monomer constituent)), which may be either linear or branched. In certain aspects, the polyolefin may be polyethylene (PE), polypropylene (PP), or a blend of PE and PP, or multi-layered structured porous films of PE and/or PP. Commercially available polyolefin porous separator26membranes include CELGARD® 2500 (a monolayer polypropylene separator) and CELGARD® 2320 (a trilayer polypropylene/polyethylene/polypropylene separator) available from Celgard LLC.

When the porous separator80is a microporous polymeric separator, it may be a single layer or a multi-layer laminate. For example, in one embodiment, a single layer of the polyolefin may form the entire microporous polymer separator80. In other aspects, the separator80may be a fibrous membrane having an abundance of pores extending between the opposing surfaces and may have a thickness of less than a millimeter, for example. As another example, however, multiple discrete layers of similar or dissimilar polyolefins may be assembled to form the microporous polymer separator80. The microporous polymer separator80may also include other polymers alternatively or in addition to the polyolefin such as, but not limited to, polyethylene terephthalate (PET), polyvinylidene fluoride (PVdF), polyamide (nylons), polyurethanes, polycarbonates, polyesters, polyetheretherketones (PEEK), polyethersulfones (PES), polyimides (PI), polyamide-imides, polyethers, polyoxymethylene (e.g., acetal), polybutylene terephthalate, polyethylenenaphthenate, polybutene, polymethylpentene, polyolefin copolymers, acrylonitrile-butadiene styrene copolymers (ABS), polystyrene copolymers, polymethylmethacrylate (PMMA), polysiloxane polymers (such as polydimethylsiloxane (PDMS)), polybenzimidazole (PBI), polybenzoxazole (PBO), polyphenylenes, polyarylene ether ketones, polyperfluorocyclobutanes, polyvinylidene fluoride copolymers (e.g., PVdF—hexafluoropropylene or (PVdF-HFP)), and polyvinylidene fluoride terpolymers, polyvinylfluoride, liquid crystalline polymers (e.g., VECTRAN™ (Hoechst AG, Germany) and ZENITE® (DuPont, Wilmington, Del.)), polyaramides, polyphenylene oxide, cellulosic materials, meso-porous silica, and/or combinations thereof.

Furthermore, the porous separator80may be mixed with a ceramic material or its surface may be coated in a ceramic material. For example, a ceramic coating may include alumina (Al2O3), silicon dioxide (SiO2), or combinations thereof. Various conventionally available polymers and commercial products for forming the separator80are contemplated.

With renewed reference toFIG. 3, in various aspects, the first positive electrode40may include a first positive current collector42and one or more first positive electroactive material layers44. The one or more first positive electroactive material layers44may be disposed in electrical communication with the first positive current collector42. For example, the first positive electroactive material layer44may be disposed at or on one or more parallel surfaces of the first positive current collector42.

In various aspects, the second positive electrode50may include a second positive current collector52and one or more second positive electroactive material layers54. The one or more second positive electroactive material layers54may be disposed in electrical communication with the second positive current collector52. For example, the second positive electroactive material layer54may be disposed at or on one or more parallel surfaces of the second positive current collector52. As illustrated, a second positive electroactive material layer54may be disposed on each opposing side of the second positive current collector52to form a bilayer structure.

The one or more first positive electroactive material layers44and the one or more second positive electroactive material layers54may each comprise a lithium-based positive electroactive material that is capable of undergoing lithium intercalation and deintercalation, absorption and desorption, alloying and dealloying, or plating and stripping, while functioning as a positive terminal of the capacitor-assisted battery30. In various aspects, the one or more first positive electroactive material layers44may comprise the same or different lithium-based positive electroactive material as the one or more second positive electroactive material layers54.

In certain variations, the one or more first positive electroactive material layer44may comprise a high energy capacity electroactive material. The one or more second positive electroactive material layer54may comprise a high power capacity electroactive material. As will be discussed further below, each electroactive layer may also include a polymeric binder and optionally a plurality of electrically conductive particles.

A high energy capacity electroactive positive material may have a specific capacity of greater than or equal to about 90 mAh/g, optionally greater than or equal to about 120 mAh/g, optionally greater than or equal to about 140 mAh/g, optionally greater than or equal to about 160 mAh/g, optionally greater than or equal to about 180 mAh/g, optionally greater than or equal to about 200 mAh/g, optionally greater than or equal to about 220 mAh/g, and in certain variations, optionally greater than or equal to about 250 mAh/g.

A high power capacity electroactive positive material may have a potential versus Li/Li+ of greater than or equal to about 1 V during lithium ion insertion and/or absorption, optionally a potential versus Li/Li+ of greater than or equal to about 1.5 V during lithium ion insertion and/or absorption.

For example, each of the one or more first positive electroactive material layers44and the one or more second positive electroactive material layers44may be defined by a plurality of positive electroactive particles (not shown) comprising one or more transition metal cations, such as manganese (Mn), nickel (Ni), cobalt (Co), chromium (Cr), iron (Fe), vanadium (V), and combinations thereof. Independent pluralities of such positive electroactive particles may be disposed in layers to define the three-dimensional structures of the one or more first positive electroactive material layers44and the one or more second positive electroactive material layers54. In certain variations, the one or more first positive electroactive material layers44and the one or more second positive electroactive material layers54may further include electrolyte100, for example a plurality of electrolyte particles (not shown). The one or more first positive electroactive material layers44and/or the one or more second positive electroactive material layers54may each have a thickness greater than or equal to about 1 μm to less than or equal to about 1,000 μm.

In various aspects, the one or more first positive electroactive material layers44and the one or more second positive electroactive material layers54may each be one of a layered-oxide cathode, a spinel cathode, and a polyanion cathode. For example, layered-oxide cathodes (e.g., rock salt layered oxides) comprises one or more lithium-based positive electroactive materials selected from LiCoO2(LCO), LiNixMnyCo1-x-yO2(where 0≤x≤1 and 0≤y≤1), LiNi1-x-yCoxAlyO2(where 0≤x≤1 and 0≤y≤1), LiNixMn1-xO2(where 0≤x≤1), and Li1+xMO2(where M is one of Mn, Ni, Co, and Al and 0≤x≤1). Spinel cathodes comprise one or more lithium-based positive electroactive materials selected from LiMn2O4(LMO) and LiNixMn1.5O4. Olivine type cathodes comprise one or more lithium-based positive electroactive material LiMPO4(where M is at least one of Fe, Ni, Co, and Mn). Polyanion cations include, for example, a phosphate such as LiV2(PO4)3and/or a silicate such as LiFeSiO4. In this fashion, the one or more first positive electroactive material layers34and the one or more second positive electroactive material layers54may each (independently) include one or more lithium-based positive electroactive materials selected from the group consisting of: LiCoO2(LCO), LiNixMnyCo1-x-yO2(where 0≤x≤1 and 0≤y≤1), LiNi1-x-yCoxAlyO2(where 0≤x≤1 and 0≤y≤1), LiNixMn1-xO2(where 0≤x≤1), Li1+xMO2(where M is one of Mn, Ni, Co, Al and 0≤x≤1), LiMn2O4(LMO), LiNixMn1.5O4, LiV2(PO4)3, LiFeSiO4, LiMPO4(where M is at least one of Fe, Ni, Co, and Mn), and combinations thereof.

As noted above, in certain variations, a high-power capacity electroactive material may be in one of the positive electrodes40,50. For example, one or more second positive electroactive material layers54in the second positive electrode50may comprise an active material, such as porous carbon materials that include activated carbons (AC), carbon xerogels, carbon nanotubes (CNTs), mesoporous carbons, templated carbons, carbide-derived carbons (CDCs), graphene, porous carbon spheres, and heteroatom-doped carbon materials. Faradaic capacitor materials may also be included, such as noble metal oxides, e.g., RuO2, transition metal oxides or hydroxides, such as MnO2, NiO, Co3O4, Co(OH)2, Ni(OH)2, and the like. Capacitance delivered by Faradaic capacitor materials is called pseudo-capacitance, which are intrinsically fast and reversible redox reactions. Other capacitor active materials may include conducting polymers, such as polyaniline (PANI), polythiophene (PTh), polyacetylene, polypyrrole (PPy), and the like. In yet other aspects, the high-power capacity electroactive material may be a lithium titanate compound selected from the group consisting of: Li4+xTi5O12, where 0≤x≤3, including lithium titanate (Li4Ti5O12) (LTO), Li4-xa/3Ti5-2xa/3CrxaO12, where 0≤xa≤1, Li4Ti5-xbScxbO12, where 0≤xb≤1, Li4-xcZnxcTi5O12, where 0≤xc≤1, Li4TiNb2O7, and combinations thereof.

In various aspects, the one or more lithium-based positive electroactive materials may be optionally coated (for example by LiNbO3and/or Al2O3) and/or may be doped (for example by magnesium (Mg)). Further, in certain variations, the one or more lithium-based positive electroactive materials may be optionally intermingled with—the one or more first positive electroactive material layers44and the one or more second positive electroactive material layers54may optionally include—one or more electrically conductive materials that provide an electron conductive path and/or at least one polymeric binder material that improves the structural integrity of the respective positive electrode40,50. For example, the one or more first positive electroactive material layers44and/or the one or more second positive electroactive material layers54may include greater than or equal to about 30 wt. % to less than or equal to about 98 wt. % of the one or more lithium-based positive electroactive materials; greater than or equal to about 0 wt. % to less than or equal to about 30 wt. % of electrically conductive materials; and greater than or equal to about 0 wt. % to less than or equal to about 20 wt. %, and in certain aspects, optionally greater than or equal to about 1 wt. % to less than or equal to about 20 wt. %, of a binder.

The one or more first positive electroactive material layers44and/or the one or more second positive electroactive material layers54may be optionally intermingled with binders such as poly(tetrafluoroethylene) (PTFE), sodium carboxymethyl cellulose (CMC), styrene-butadiene rubber (SBR), poly(vinylidene fluoride) (PVDF), nitrile butadiene rubber (NBR), styrene ethylene butylene styrene copolymer (SEBS), styrene butadiene styrene copolymer (SBS), lithium polyacrylate (LiPAA), sodium polyacrylate (NaPAA), sodium alginate, lithium alginate, and combinations thereof. Electrically conductive materials may include carbon-based materials, powder nickel or other metal particles, or a conductive polymer. Carbon-based materials may include, for example, particles of carbon black, graphite, acetylene black (such as KETCHEN™ black or DENKA™ black), carbon fibers and nanotubes, graphene, and the like. Examples of a conductive polymer include polyaniline, polythiophene, polyacetylene, polypyrrole, and the like.

The first and second positive current collectors42,52may facilitate the flow of electrons between the positive electrodes40,50and an exterior circuit. For example, an interruptible external circuit120and a load device130may connect the first positive electrode40(through the first positive current collector42) and the second positive electrode50(through the second positive current collector52). The positive current collectors42,52may include metal, such as a metal foil, a metal grid or screen, or expanded metal. For example, the positive current collectors42,52may be formed from aluminum, stainless steel and/or nickel or any other appropriate electrically conductive materials known to those of skill in the art. In various aspects, the first and second positive current collectors42,52may be the same or different.

In various aspects, the negative electrode60may include a first negative current collector62and one or more first negative electroactive material layers64. The one or more first negative electroactive material layers64may be disposed in electrical communication with the first negative current collector62. For example, the one or more first negative electroactive material layers64may be disposed at or near one or more parallel surfaces of the first negative current collector62. As illustrated, a first negative electroactive material layer64may be disposed both at or on the first negative current collector62, for example, to define a bilayer structure.

Like the positive current collectors42,52, the first negative current collector62may include metal, such as a metal foil, a metal grid or screen, or expanded metal. For example, the first negative current collector62may be formed from copper, aluminum or any other appropriate electrically conductive material known to those of skill in the art. The one or more first negative electroactive material layers64may comprise a lithium host material (e.g., negative electroactive material) that is capable for functioning as a negative terminal of the capacitor-assisted battery30. The one or more first negative electroactive material layers64may be defined by a plurality of negative electroactive particles (not shown) that are lithium based. For example, the electroactive material may include a lithium metal and/or lithium alloy; silicon based, comprising, for example, a silicon or silicon alloy or silicon oxide. The electroactive material may also include graphite; carbonaceous material, comprising, for example, one or more of activated carbon (AC), activated carbon (AC), hard carbon (HC), soft carbon (SC), graphite, graphene, and carbon nanotubes (“CNTs”); and/or comprising one or more lithium-accepting anode materials such as lithium titanium oxide (Li4Ti5O12), one or more transition metals (such as tin (Sn)), one or more metal oxides (such as vanadium oxide (V2O5), titanium dioxide (TiO2)), titanium niobium oxide (TixNbyOz, where 0≤x≤2, 0≤y≤24, and 0≤z≤64), and one or more metal sulfides (such as ferrous sulfide (FeS)).

The one or more first negative electroactive material layers64may each include a negative electroactive material selected from the group consisting of: lithium metal, lithium alloy, silicon (Si), silicon alloy, silicon oxide, activated carbon (AC), hard carbon (HC), soft carbon (SC), graphite, graphene, carbon nanotubes, lithium titanium oxide (Li4Ti5O12), tin (Sn), vanadium oxide (V2O5), titanium dioxide (TiO2), titanium niobium oxide (TixNbyOz, where 0≤x≤2, 0≤y≤24, and 0≤z≤64), ferrous sulfide (FeS), and combinations thereof. The one or more first negative electroactive material layers64may each have a thickness greater than or equal to about 1 μm to less than or equal to about 1,000 μm.

In certain variations, the one or more first negative electroactive material layers64may comprise a high-energy capacity electroactive material. As will be described below, the one or more second negative electroactive material layers74in the second negative electrode70may comprise a high power capacity electroactive material. The high-energy capacity negative electroactive material may be selected from the group consisting of: carbon-containing materials, silicon, silicon-containing alloys, tin-containing alloys, and combinations thereof. In certain variations, the high-energy capacity electroactive material comprises a carbon-containing compound, such as disordered carbons and graphitic carbons/graphite.

In certain variations, the high-power capacity electroactive material may be in one of the negative electrodes60,70and comprise an active material, such as porous carbon materials that include activated carbons (AC), carbon xerogels, carbon nanotubes (CNTs), mesoporous carbons, templated carbons, carbide-derived carbons (CDCs), graphene, porous carbon spheres, and heteroatom-doped carbon materials. Faradaic capacitor materials may also be included, such as noble metal oxides, e.g., RuO2, transition metal oxides or hydroxides, such as MnO2, NiO, Co3O4, Co(OH)2, Ni(OH)2, and the like. Capacitance delivered by Faradaic capacitor materials is called pseudo-capacitance, which are intrinsically fast and reversible redox reactions. Other capacitor active materials may include conducting polymers, such as polyaniline (PANI), polythiophene (PTh), polyacetylene, polypyrrole (PPy), and the like. In yet other aspects, the high-power capacity electroactive material may be a lithium titanate compound selected from the group consisting of: Li4+xTi5O12, where 0≤x≤3, including lithium titanate (Li4Ti5O12) (LTO), Li4-xa/3Ti5-2xa/3CrxaO12, where 0≤xa≤1, Li4Ti5-xbScxbO12, where 0≤xb≤1, Li4-xcZnxcTi5O12, where 0≤xc≤1, Li4TiNb2O7, and combinations thereof.

In certain other aspects, the negative electrode may comprise a negative electroactive material selected from the group consisting of: lithium metal, lithium alloy, silicon (Si), silicon alloy, silicon oxide, activated carbon, hard carbon, soft carbon, graphite, graphene, carbon nanotubes, lithium titanium oxide (Li4Ti5O12), tin (Sn), vanadium oxide (V2O5), titanium dioxide (TiO2), titanium niobium oxide (TixNbyOzwhere 0≤x≤2, 0≤y≤24, and 0≤z≤64), ferrous sulfide (FeS), and combinations thereof.

In various aspects, the one or more negative electroactive materials may be optionally intermingled with one or more electrically conductive materials that provide an electron conductive path and/or at least one polymeric binder material that improves the structural integrity of the one or more electroactive material layers64in the negative electrode60. For example, the one or more first negative electroactive material layers64may include greater than or equal to about 0 wt. % to less than or equal to about 99 wt. % of the negative electroactive material; greater than or equal to about 0 wt. % to less than or equal to about 30 wt. % of electrically conductive materials; and greater than or equal to about 0 wt. % to less than or equal to about 20 wt. %, and in certain aspects, optionally greater than or equal to about 1 wt. % to less than or equal to about 20 wt. % of a binder.

The one or more first negative electroactive material layers64may be optionally intermingled with binders such as poly(tetrafluoroethylene) (PTFE), sodium carboxymethyl cellulose (CMC), styrene-butadiene rubber (SBR), poly(vinylidene fluoride) (PVDF), nitrile butadiene rubber (NBR), styrene ethylene butylene styrene copolymer (SEBS), styrene butadiene styrene copolymer (SBS), lithium polyacrylate (LiPAA), sodium polyacrylate (NaPAA), sodium alginate, lithium alginate, and combinations thereof. Electrically conductive materials may include carbon-based materials, powder nickel or other metal particles, or a conductive polymer. Carbon-based materials may include, for example, particles of carbon black, graphite, acetylene black (such as KETCHEN™ black or DENKA™ black), carbon fibers and nanotubes, graphene, and the like. Examples of a conductive polymer include polyaniline, polythiophene, polyacetylene, polypyrrole, and the like.

In various aspects, the fourth negative electrode70may include a second negative current collector72and one or more second negative electroactive material layers74. The one or more second negative electroactive material layers74may disposed in electrical communication with the second negative current collector72. For example, the one or more second negative electroactive material layers74may be disposed at or on one or more parallel surfaces of the second negative current collector72. The one or more second negative electroactive material layers74may comprise an electroactive material like those discussed in the context of the first negative electrode60.

Like the first negative current collector72, the second negative current collector72may include metal, such as a metal foil, a metal grid or screen, or expanded metal. For example, the second negative current collector72may be formed from copper, aluminum or any other appropriate electrically conductive material known to those of skill in the art. The second negative current collector72may be same or different from the first negative current collector62. The first and second negative current collectors62,72may facilitate the flow of electrons between the negative electrodes60,70and the exterior circuit120. For example, the interruptible external circuit120and the load device130may connect the first negative electrode60(through the first negative current collector62) and the second negative electrode70(through the second positive current collector72) either in series or parallel.

In certain variations, the first positive electrode may comprise a high energy capacity positive electroactive material. The second positive electrode may comprise a high power capacity electroactive material. The third negative electrode and the fourth negative electrode may comprise the same negative electroactive material. The first positive electrode and the third negative electrode define a lithium-ion battery. The second positive electrode and the fourth negative electrode define a capacitor.

FIGS. 4A-4B and 5show components that form a capacitor-assisted hybrid lithium-ion electrochemical cell assembly150prepared in accordance with certain aspects of the present disclosure having electrode components to reduce current density during high power charging and discharging with tabs on four distinct edges. A first positive electrode160has a first polarity and defines four lateral edges, including two edges162having a first dimension152(e.g., length). The two edges162are parallel and opposite to one another across the first positive electrode160. There are also two edges164having a second dimension154(e.g., length) greater than the first dimension, which are also parallel, but opposite to one another across the first positive electrode160. In this manner, the first positive electrode160defines a generally rectangular shape. It should be noted that in alternative variations, the rectangular shape may in fact be a square where the first length of two edges162and second length of two edges164may be the same. This is true for any of the rectangular shapes discussed herein.

The first positive electrode160has two first electrically conductive tabs166disposed on at least one edge162having the first length and at least one edge164having the second length. As shown inFIG. 4B, the first electrically conductive tabs166are disposed on all four edges, so that the first positive electrode160has four first electrically conductive tabs166. Each tab166is positioned at a location on a first side168of the respective edges162,164. Each tab166has a width156and a height158. Each tab has a width156that occupies less than half of the length of each edge, for example, a tab width156may be greater than or equal to about 20% to less than or equal to about 45% of an overall length of each respective edge. In certain aspects, a height158of the tab166may be greater than or equal to about 5 mm to less than or equal to about 30 mm. In certain other aspects, a width156of the tab166may be greater than or equal to about 30 mm to less than or equal to about 300 mm. While each of the tabs166may have the same dimensions and rectangular shape, they may also be varied in dimensions and shape from edge to edge.

The first positive electrode160comprises a current collector having an electroactive layer disposed thereon. In certain variations, the current collector defines the plurality of electrically conductive tabs166. Thus, the electrically conductive tabs166may be formed from the same material as a current collector, for example, a metal foil.

Also shown is a second positive electrode170having the same first polarity as the first positive electrode160. In certain variations, the second positive electrode170may comprise a distinct active material from the first positive electrode160. The second positive electrode170defines four lateral edges, including two edges172having a first dimension (e.g., length). The two edges172are parallel and opposite to one another across the second positive electrode170. There are also two edges174having a second dimension (e.g., length) greater than the first dimension, which are also parallel, but opposite to one another across the second positive electrode170. In this manner, the second positive electrode170defines a generally rectangular shape.

The second positive electrode170has least two first electrically conductive tabs176disposed on at least one edge172having the first length and at least one edge174having the second length. As shown inFIG. 4B, the first electrically conductive tabs176are disposed on all four edges, so that the second positive electrode170has four second electrically conductive tabs176. Each tab176is positioned at a location on a first side178of the respective edges162,164. The first side168of the first positive electrode160corresponds to the first side178of the second positive electrode170, so that the tabs166,176may be aligned, superimposed, and connected together. Each tab176may have the same properties and dimensions as tabs166described in the context of the first positive electrode160.

The second positive electrode170also comprises a current collector having an electroactive layer disposed thereon. In certain variations, the current collector further defines the plurality of second electrically conductive tabs176. Thus, the second electrically conductive tabs176may be formed from the same material as a current collector, for example, a metal foil.

The next component in the capacitor-assisted hybrid lithium-ion electrochemical cell assembly150is a separator180that provides an electrical barrier between the first and second positive electrodes160,170and the negative electrodes to be described herein.

Third negative electrode190has a second polarity opposite to the first polarity. The electrode190defines four lateral edges, including two edges192having a first dimension (e.g., length). The two edges192are parallel and opposite to one another across the electrode190. There are also two edges164having a second dimension (e.g., length) greater than the first dimension, which are also parallel, but opposite to one another across the electrode190. In this manner, the electrode190defines a generally rectangular shape. The electrode190has least two first electrically conductive tabs196disposed on at least one edge192having the first length and at least one edge194having the second length. The third electrically conductive tabs196are disposed on all four edges, so that the electrode190has four third electrically conductive tabs196. Each tab196is positioned at a location on a second side198of the respective edges192,194. Notably, the second side198is opposite to the first sides168,178along the edges of the first positive electrodes160,170when they are superimposed onto one another. Each tab196occupies less than half of an overall length of each edge, for example, a tab width may be greater than or equal to about 20% to less than or equal to about 45% of an overall length of each respective edge. In certain aspects, a height of the tab196may be greater than or equal to about 5 mm to less than or equal to about 30 mm. In certain other aspects, a width of the tab196may be greater than or equal to about 30 mm to less than or equal to about 300 mm. While each of the tabs196may have the same dimensions and rectangular shape, they may also be varied in dimensions and shape from edge to edge.

The third negative electrode190comprises a current collector having an electroactive layer disposed thereon. In certain variations, the current collector defines the third plurality of electrically conductive tabs196. Thus, the third electrically conductive tabs196may be formed from the same material as a current collector, for example, a metal foil.

A fourth negative electrode200has the same second polarity as the third negative electrode190. In certain variations, the fourth negative electrode200may comprise a distinct active material from the third negative electrode190. In other variations, the third and fourth negative electrodes190,200may comprise the same active material. The fourth negative electrode200defines four lateral edges, including two edges202having a first dimension (e.g., length). The two edges202are parallel and opposite to one another across the electrode200. There are also two edges204having a second dimension (e.g., length) greater than the first dimension, which are also parallel, but opposite to one another across the electrode200. In this manner, the electrode200defines a generally rectangular shape.

The fourth negative electrode200has at least two fourth electrically conductive tabs206disposed on at least one edge192having the first length and at least one edge194having the second length. The fourth electrically conductive tabs206are disposed on all four edges, so that the electrode200has four first electrically conductive tabs206. Each tab206is positioned at a location on a first side208of the respective edges202,204. The second side198of the third negative electrode190corresponds to the first side208of the electrode200, so that they may be aligned, superimposed, and connected together. Each fourth tab206may have the same properties and dimensions as tabs196described in the context of the third negative electrode190or first positive tab166.

The fourth negative electrode200also comprises a current collector having an electroactive layer disposed thereon. In certain variations, the current collector defines the fourth plurality of electrically conductive tabs206. Thus, the electrically conductive tabs206may be formed from the same material as a current collector, for example, a metal foil.

The first positive electrode160, the second positive electrode170, the separator180, the third negative electrode190, and the fourth negative electrode200are then stacked together to form a core cell assembly210. As will be appreciated by those of skill in the art, while not shown in4A-4B and5, the order and arrangement of components may differ from those shown. For example, in one variation, a core cell assembly may include the first positive electrode160, separator180, third negative electrode190, another separator180, the second positive electrode170, separator180and fourth negative electrode200stacked together to form a core cell assembly. In the core cell assembly210, each edge212defines a first side214and a second side216. Notably, the sides are defined with respect to each edge and change orientation for opposite parallel sides. The first side214corresponds to the first side168of first positive electrode160and first side178of the second positive electrode170. As noted above, the plurality of the first electrically conductive tabs166of the first positive electrode160substantially align with the plurality of second electrically conductive tabs176of the second positive electrode170on the first side214when they are assembled in a stack and thus form common positive tabs218. By substantially align, it is meant that the tabs generally have the same dimensions and thus align with one another when stacked, but there may be some small deviation in tolerances or alignment as a result of typical manufacturing processes. Likewise, the plurality of third electrically conductive tabs196of the third negative electrode190substantially align with the plurality of fourth electrically conductive tabs206of the fourth negative electrode200on the second side216when they are assembled in a stack and thus form common negative tabs220.

The core cell assembly210is incorporated into and forms the capacitor-assisted hybrid lithium-ion electrochemical cell assembly150. The common positive tabs218may be welded together and appropriately capped or sheathed to form a plurality of positive electrical connectors230. The positive electrical connectors230may be connected to other electrical conduits with the same polarity, such as bus bars, circuitry, or may themselves form terminals for external connection to a load and power source. For example, certain examples of formation of the electrical connectors may include using a one-step ultrasonic welding to weld the electrode tab foil with external terminals (e.g., outside tabs for forming the final cell). Alternatively, ultrasonic welding can be first used to weld the electrode tab foil, and then use ultrasonic welding to weld foil with external terminals. In another example, ultrasonic welding can be used to weld the electrode tab foil first, and then laser and/or resistance welding can be used to weld foil with external terminals. In certain aspects, an external terminal material for a positive electrode comprises aluminum, by way of example.

Similarly, the common negative tabs220may be welded together and appropriately capped or sheathed to form a plurality of negative electrical connectors232. The negative electrical connectors232may be connected to other electrical conduits with the same polarity, such as bus bars, circuitry, or may themselves form terminals for external connection to loads, generators, or power sources and the like in the same manner as described above in the context of the positive electrical connector230. In certain aspects, an external terminal material for a negative electrode comprises aluminum, copper, nickel, and nickel-coated copper, by way of example. The capacitor-assisted hybrid lithium-ion electrochemical cell assembly150can be incorporated into other components, such as a housing or pouch.

Each edge234of the capacitor-assisted hybrid lithium-ion electrochemical cell assembly150has both a positive electrical connector and a spaced apart negative electrical connector. The plurality of positive and negative electrical connectors on each edge of the electrochemical cell serves to distribute current more uniformly during operation and lithium ion cycling, thus minimizing variations in current and minimizing current density within the high powered cell, as shown inFIG. 4B. More specifically, by including eight tabs, where two tabs are connected to positive or negative electrical connectors on each lateral edge, this design reduces the current and current density carried by any one of the tabs connected to positive or negative electrical connectors, which is particularly advantageous for ultra-high power applications. This in turns serves to reduce hot spots and diminish thermal gradients during high power charge and discharge conditions. By way of example, where performance of a capacitor-assisted hybrid lithium-ion electrochemical cell assembly having eight tabs prepared in accordance with certain aspects of the present disclosure is compared to a conventional two tab design for a comparative capacitor-assisted hybrid lithium-ion electrochemical cell assembly with the same materials, a maximum current density is decreased by greater than or equal to about 50%, optionally greater than or equal to about 60%, optionally greater than or equal to about 70%, and in certain variations, optionally greater than or equal to about 75%. A reduction in maximum current density favorably reduces thermal gradients, which are affected by charge/discharge currents. The higher the current (or current density), the larger the thermal gradient. Thus, minimizing the current density serves to favorably reduce thermal gradients.

Generally, an electrochemical cell can refer to a unit that can be connected to other units. A plurality of electrically connected cells, for example, those that are stacked together, may be considered to be a module. A pack generally refers to a plurality of operatively-connected modules, which may be electrically connected in various combinations of series or parallel connections. The battery module may thus be encased in a pouch structure, a housing, or located with a plurality of other battery modules to form a battery pack. In certain aspects, the battery module may be part of a prismatic hybrid cell battery.

FIG. 5shows exploded view of various components in a capacitor-assisted hybrid lithium-ion electrochemical cell assembly prepared in accordance with certain aspects of the present disclosure like that inFIGS. 4A-4B, showing current distribution within each of the electrodes160,170,190, and200that would occur in the stacked and assembled device.

In certain aspects, either the first positive electrode160or third negative electrode190comprises a high energy capacity electroactive material and the second positive electrode170or the fourth negative electrode200comprises a high power capacity electroactive material. In this manner, the first positive electrode160and the third negative electrode190define a lithium-ion battery within the capacitor-assisted hybrid lithium-ion electrochemical cell assembly150, while the second positive electrode170and the fourth negative electrode200define a capacitor within the capacitor-assisted hybrid lithium-ion electrochemical cell assembly150. In certain aspects, the first positive electrode160comprises a high energy capacity electroactive material, the second positive electrode170comprises a high power capacity electroactive material, such as a capacitor material. The corresponding third and fourth negative electrodes190,200may be compatible negative electroactive materials for the respective lithium-ion battery and the capacitor. As will be appreciated by those of skill in the art, the various embodiments of capacitor-assisted hybrid lithium-ion electrochemical cell assemblies described in the context of the present disclosure are not limited to a single capacitor electrode, but rather may have a plurality of capacitors stacked within the cell core assembly at any location. Thus, a capacitor hybridization ratio can be tuned by the number of capacitor electrode layers included in the assembly. The capacitor-assisted hybrid lithium-ion electrochemical cell assembly150may be formed by an intermittent coating process forming discrete electrodes on a current collector foil, where the tabs are notched into each respective discrete electrode in the appropriate positions along lateral edges.

FIGS. 6A-6Bshow components of another variation of a capacitor-assisted hybrid lithium-ion electrochemical cell assembly250prepared in accordance with certain aspects of the present disclosure having electrode components with tabs on three distinct edges. For brevity, unless otherwise specifically addressed, the components of the capacitor-assisted hybrid lithium-ion electrochemical cell assembly250having the same design, function, and/or dimensions as those in the capacitor-assisted hybrid lithium-ion electrochemical cell assembly150previously described will not be described again in detail, but may share the same properties and dimensions as discussed above.

A first positive electrode260includes two edges262with a first length and two edges264with a second length, which may be greater than the first length. The first positive electrode260has three first electrically conductive tabs266. One tab266is disposed on one edge262having the first length and two tabs266are disposed respectively on two edges264having the second length. Thus, the first electrically conductive tabs266are disposed on three of four lateral edges of the first positive electrode260, so that one lateral edge is free of a tab. Each tab266is positioned at a location on a first side268of the respective edges262,264.

Also shown is a second positive electrode270. In certain variations, the second positive electrode270may comprise a distinct active material from the first positive electrode260. The second positive electrode270includes two edges272with a first length and two edges274with a second length, optionally greater than the first length. The second positive electrode270has three second electrically conductive tabs276. One tab276is disposed on one edge272having the first length and two tabs276are disposed on two edges274having the second length. Thus, the first electrically conductive tabs276are disposed on three of four lateral edges of the second positive electrode270, so that one lateral edge is free of any tabs. Each tab276is positioned at a location on a first side278of the respective edges272,274.

A separator280is included. A third negative electrode290includes two edges292with a first length and two edges294with a second length optionally greater than the first length. The third negative electrode290has three third electrically conductive tabs296. One tab296is disposed on one edge292having the first length and two tabs296are disposed respectively on two edges294having the second length. Thus, the third electrically conductive tabs296are disposed on three of four lateral edges of the third negative electrode290, so that one edge is free of any tabs. Each tab296is positioned at a location on a first side298of the respective edges292,294.

A fourth negative electrode300includes two edges302with a first length and two edges304with a second length optionally greater than the first length. In certain variations, the fourth negative electrode300may comprise a distinct active material from the third negative electrode290. The fourth negative electrode300has three fourth electrically conductive tabs306. One tab306is disposed on one edge302having the first length and two tabs306are disposed respectively on two edges304having the second length. Thus, the fourth electrically conductive tabs306are disposed on three of four lateral edges, so that one edge is free of and does not have any tabs. Each tab306is positioned at a location on a first side308of the respective edges302,304.

The first positive electrode260, the second positive electrode270, the separator280, the third negative electrode290, and the fourth negative electrode300are then stacked together to form a core cell assembly310. In the core assembly310, each edge312defines a position at a first side314and a position at a second side316. The first side314corresponds to the first side268of first positive electrode260and first side278of the second positive electrode270. The plurality of the first electrically conductive tabs266of the first positive electrode260substantially align with the plurality of second electrically conductive tabs276of the second positive electrode270on the first side314when they are assembled together (e.g., stacked) and thus form common positive tabs318. Likewise, the plurality of third electrically conductive tabs296of the third negative electrode290substantially align with the plurality of fourth electrically conductive tabs306of the fourth negative electrode300on the second side316when they are assembled in a stack and thus form common negative tabs320.

The core cell assembly310then is incorporated into and forms the capacitor-assisted hybrid lithium-ion electrochemical cell assembly250. The common positive tabs318may be welded together and appropriately capped or sheathed to form a plurality of positive electrical connectors330. The positive electrical connectors330may be connected to other electrical conduits with the same polarity, such as bus bars, circuitry, or may themselves form terminals for external connection to loads, generators, or power sources and the like. Such a process may be similar to that previously described and will not be repeated herein. Similarly, the common negative tabs320may be welded together and appropriately capped or sheathed to form a plurality of negative electrical connectors332. The negative electrical connectors332may be connected to other electrical conduits with the same polarity, such as bus bars, circuitry, or may themselves form terminals for external connection to loads, generators, or power sources and the like. The capacitor-assisted hybrid lithium-ion electrochemical cell assembly150can be incorporated into other components, such as a housing or pouch340prior to or after forming the positive electrical connector330and negative electrical connector332.

Three of four lateral edges334of the capacitor-assisted hybrid lithium-ion electrochemical cell assembly250have both a positive electrical connector330and a spaced apart negative electrical connector332(corresponding to the first side314and second side316of each lateral edge312). The plurality of positive and negative electrical connectors330,332on three edges of the electrochemical cell serves to distribute current more uniformly during operation and lithium ion cycling, thus minimizing variations in current and minimizing current density within the high powered cell, as shown inFIG. 6B. Again, by including six tabs, where two tabs are connected to positive or negative electrical connectors on three lateral edges of the electrochemical cell assembly, this design reduces the current and current density carried by any one of the tabs connected to positive or negative electrical connectors, which is particularly advantageous for ultra-high power applications. This in turns serves to reduce hot spots and diminish thermal gradients during high power charge and discharge conditions. By way of example, where performance of a capacitor-assisted hybrid lithium-ion electrochemical cell assembly having six tabs prepared in accordance with certain aspects of the present disclosure is compared to a conventional two tab design for a comparative capacitor-assisted hybrid lithium-ion electrochemical cell assembly with the same materials, a maximum current density is decreased by greater than or equal to about 45%, optionally greater than or equal to about 50%, optionally greater than or equal to about 60%, and in certain variations, optionally greater than or equal to about 70%. A reduction in maximum current density favorably reduces thermal gradients, which are affected by charge/discharge currents. The higher the current (or current density), the larger the thermal gradient. Thus, minimizing the current density serves to favorably reduce thermal gradients.

The capacitor-assisted hybrid lithium-ion electrochemical cell assembly250may be formed by an intermittent coating process forming discrete electrodes on a current collector foil, where the tabs are notched into each respective discrete electrode in the appropriate positions along lateral edges.

FIGS. 7A-7Bshow components of another variation of a capacitor-assisted hybrid lithium-ion electrochemical cell assembly350prepared in accordance with certain aspects of the present disclosure having electrode components with tabs on three distinct edges. For brevity, unless otherwise specifically addressed, the components of the capacitor-assisted hybrid lithium-ion electrochemical cell assembly350having the same design, function, and dimensions as those in the capacitor-assisted hybrid lithium-ion electrochemical cell assembly150inFIGS. 4A-4Bpreviously described will not be described again in detail, but will be understood to share the same properties and dimensions as discussed above.

A first positive electrode360includes two edges362with a first length and two edges364with a second length, which may be greater than the first length. The first positive electrode360has three first electrically conductive tabs366. One tab366is disposed on one edge362having the first length and two tabs366are disposed respectively on two edges364having the second length. Thus, the first electrically conductive tabs366are disposed on three of four lateral edges of the first positive electrode360, so that one lateral edge is free of a tab. The tabs366on the first edge364are positioned at a location corresponding to a first side368of the respective edge364. However, the tab366on the edge362with the first length is disposed at a location corresponding to a central region369of the edge362.

Also shown is a second positive electrode370. In certain variations, the second positive electrode370may comprise a distinct active material from the first positive electrode360. A second positive electrode370includes two edges372with a first length and two edges374with a second length, which may be greater than the first length. The second positive electrode370has three first electrically conductive tabs376. One tab376is disposed on one edge372having the first length and two tabs376are disposed respectively on two edges374having the second length. Thus, the first electrically conductive tabs766are disposed on three of four lateral edges of the second positive electrode370, so that one lateral edge is free of a tab. The tabs376on the first edge374are positioned at a location corresponding to a first side378of the respective edge374. However, the tab376on the edge372with the first length is disposed at a location corresponding to a central region379of the edge372.

A separator380is included. A third negative electrode390includes two edges392with a first length and two edges394with a second length optionally greater than the first length. The third negative electrode390has three third electrically conductive tabs396. One tab396is disposed on one edge392having the first length and two tabs396are disposed respectively on two edges394having the second length. Thus, the third electrically conductive tabs396are disposed on three of four lateral edges of the third negative electrode390, so that one edge is free of any tabs. Two tabs396on the two edges294with the second length are positioned at a location on a first side398. However, the tab396on the edge392with the first length is disposed at a location corresponding to a central region399of the edge392.

A fourth negative electrode400may comprise a distinct active material from the third negative electrode390. The fourth negative electrode400includes two edges402with a first length and two edges404with a second length optionally greater than the first length. The fourth negative electrode400has three fourth electrically conductive tabs406. One tab406is disposed on one edge402having the first length and two tabs406are disposed respectively on two edges404having the second length. Thus, the fourth electrically conductive tabs406are disposed on three of four lateral edges, so that one edge is free of and does not have any tabs. Two tabs406on the two edges404with the second length are positioned at a location on a first side408. However, the tab406on the edge402with the first length is disposed at a location corresponding to a central region409of the edge402.

The first positive electrode360, the second positive electrode370, the separator380, the third negative electrode390, and the fourth negative electrode400are then stacked together to form a core cell assembly410. In the core assembly410, edges412having the second length define a position at a first side414and a position at a second side416. The first side414corresponds to the first side368of first positive electrode360and first side378of the second positive electrode370. The plurality of the first electrically conductive tabs366of the first positive electrode360substantially align with the plurality of second electrically conductive tabs376of the second positive electrode370on the first side414when they are assembled together (e.g., stacked) and thus form common positive tabs418. Likewise, edges412having the second length includes the plurality of third electrically conductive tabs396of the third negative electrode390substantially aligned with the plurality of fourth electrically conductive tabs406of the fourth negative electrode400on the second side416. When they are assembled (e.g., stacked) they form thus form common negative tabs420. Further, opposite edges422having the first length each have either common positive tab418or a common negative tab420. The common positive tab418on edge422is formed by substantially aligning the first electrically conductive tabs366of the first positive electrode360substantially align with the plurality of second electrically conductive tabs376of the second positive electrode370. The common negative tab420on opposite edge422having the second length is formed by substantially aligning the plurality of third electrically conductive tabs396of the third negative electrode390with the plurality of fourth electrically conductive tabs406of the fourth negative electrode400.

The core cell assembly410then is incorporated into and forms the capacitor-assisted hybrid lithium-ion electrochemical cell assembly350. The common positive tabs418may be welded together and appropriately capped or sheathed to form a plurality of positive electrical connectors430. The positive electrical connectors330may be connected to other electrical conduits with the same polarity, such as bus bars, circuitry, or may themselves form terminals for external connection to loads, generators, or power sources and the like. Similarly, the common negative tabs420may be welded together and appropriately capped or sheathed to form a plurality of negative electrical connectors432. The negative electrical connectors432may be connected to other electrical conduits with the same polarity, such as bus bars, circuitry, or may themselves form terminals for external connection to loads, generators, or power sources and the like. The capacitor-assisted hybrid lithium-ion electrochemical cell assembly350can be incorporated into other components, such as a housing or pouch440prior to or after forming the positive electrical connector430and negative electrical connector432.

Two of four lateral edges434of the capacitor-assisted hybrid lithium-ion electrochemical cell assembly350have both a positive electrical connector430and a spaced apart negative electrical connector432(corresponding to the first side414and second side416of each lateral edge412). Further, each of opposing lateral edges436has one of either a positive electrical connector430or a negative electrical connector432. Thus, two edges of the electrochemical cell assembly have both a positive electrical connector and a spaced apart negative electrical connector, one edge has a single positive electrical connector, and an opposite edge has a single negative electrical connector.

The plurality of positive and negative electrical connectors430,432on four edges of the electrochemical cell serves to distribute current more uniformly during operation and lithium ion cycling, thus minimizing variations in current and minimizing current density within the high powered cell. By including six tabs integrally formed with and connected to positive or negative electrical connectors on four lateral edges of the electrochemical cell assembly, current and current density carried by any one of the tabs are minimized, which is particularly advantageous for ultra-high power applications. This in turns serves to reduce hot spots and diminish thermal gradients during high power charge and discharge conditions, as previously discussed.

The capacitor-assisted hybrid lithium-ion electrochemical cell assembly350may be formed by an intermittent coating process forming discrete electrodes on a current collector foil, where the tabs are notched into each respective discrete electrode in the appropriate positions along lateral edges.

FIGS. 8A-8Bshow components of another variation of a capacitor-assisted hybrid lithium-ion electrochemical cell assembly450prepared in accordance with certain aspects of the present disclosure having electrode components with tabs on two distinct parallel lateral edges. For brevity, unless otherwise specifically addressed, the components of the capacitor-assisted hybrid lithium-ion electrochemical cell assembly450having the same design, function, and/or dimensions as those in the capacitor-assisted hybrid lithium-ion electrochemical cell assembly150inFIGS. 4A-4Bpreviously described will not be described again in detail, but will be understood to share the same properties and dimensions as discussed above.

A first positive electrode460includes two edges462with a first length and two edges464with a second length, which may be greater than the first length. The first positive electrode460has two first electrically conductive tabs466. One tab466is disposed on each of two edges464having the second length. Thus, the first electrically conductive tabs466are disposed on two of four lateral edges of the first positive electrode460, so that two lateral edges462are free of any tabs. Each of the tabs466on the first edge464are positioned at a location corresponding to a first side468of the respective edge464.

Also shown is a second positive electrode470. In certain variations, the second positive electrode470may comprise a distinct active material from the first positive electrode460. A second positive electrode470includes two edges472with a first length and two edges474with a second length, which may be greater than the first length. The second positive electrode470has two first electrically conductive tabs476. One tab476is disposed on each of two edges474having the second length. Thus, the first electrically conductive tabs476are disposed on two of four lateral edges of the second positive electrode470, so that two lateral edges472are free of any tabs. The tabs476on the first edge474are positioned at a location corresponding to a first side478of the respective edge474.

A separator480is included. A third electrode490includes two edges492with a first length and two edges494with a second length optionally greater than the first length. The third negative electrode490has two third electrically conductive tabs496. One tab496is disposed on each of two edges494having the second length. Thus, the third electrically conductive tabs496are disposed on two of four lateral edges of the third negative electrode390, so that two edges are free of any tabs. Two tabs496on the two edges494with the second length are positioned at a location on a first side498.

A fourth negative electrode500includes two edges502with a first length and two edges504with a second length optionally greater than the first length. The fourth negative electrode500may comprise a distinct active material from the third negative electrode490. The fourth negative electrode500has two fourth electrically conductive tabs506. One tab506is disposed on each of two edges504having the second length. Thus, the fourth electrically conductive tabs506are disposed on two of four lateral edges, so that two edges502are free of and do not have any tabs. Two tabs506on the two edges504with the second length are positioned at a location on a first side508.

The first positive electrode460, the second positive electrode470, the separator480, the third negative electrode490, and the fourth negative electrode500are then stacked together to form a core cell assembly510. In the core assembly510, edges512having the second length define a position at a first side514and a position at a second side516. The first side514corresponds to the first side468of first positive electrode460and first side478of the second positive electrode470. The plurality of the first electrically conductive tabs466of the first positive electrode460substantially align with the plurality of second electrically conductive tabs476of the second positive electrode470on the first side514when they are assembled together (e.g., stacked) and thus form common positive tabs518. Likewise, edges512having the second length include the plurality of third electrically conductive tabs496of the third negative electrode490substantially aligned with the plurality of fourth electrically conductive tabs506of the fourth negative electrode500on the second side516. When they are assembled (e.g., stacked) they form thus form common negative tabs520.

The core cell assembly510then is incorporated into and forms the capacitor-assisted hybrid lithium-ion electrochemical cell assembly450. The common positive tabs518may be welded together and appropriately capped or sheathed to form a plurality of positive electrical connectors530. The positive electrical connectors530may be connected to other electrical conduits with the same polarity, such as bus bars, circuitry, or may themselves form terminals for external connection to loads, generators, or power sources and the like. Similarly, the common negative tabs520may be welded together and appropriately capped or sheathed to form a plurality of negative electrical connectors532. The negative electrical connectors532may be connected to other electrical conduits with the same polarity, such as bus bars, circuitry, or may themselves form terminals for external connection to loads, generators, or power sources and the like. The capacitor-assisted hybrid lithium-ion electrochemical cell assembly450can be incorporated into other components, such as a housing or pouch540prior to or after forming the positive electrical connector530and negative electrical connector532.

Two parallel lateral edges534of the four edges of the capacitor-assisted hybrid lithium-ion electrochemical cell assembly450have both a positive electrical connector530and a spaced apart negative electrical connector532(corresponding to the first side514and second side516of each lateral edge512). Further, each of opposing lateral edges536is free of any tabs. Thus, two opposite edges of the electrochemical cell assembly have both a positive electrical connector and a spaced apart negative electrical connector to define a four-tab hybrid design.

The plurality of positive and negative electrical connectors530,532on two edges of the electrochemical cell serves to distribute current more uniformly during operation and lithium ion cycling, thus minimizing variations in current and minimizing current density within the high powered cell. By including four tabs integrally formed with and connected to positive or negative electrical connectors on two opposing parallel lateral edges of the electrochemical cell assembly, current and current density carried by any one of the tabs is improved for better thermal distribution, especially during high power charge and discharge conditions.

The capacitor-assisted hybrid lithium-ion electrochemical cell assembly450may be formed by a continuous electrode coating process where tabs can be created on two sides of a continuously deposited electrode that is intermittently cut at appropriate intervals. Alternatively, the capacitor-assisted hybrid lithium-ion electrochemical cell assembly450may be formed by an intermittent coating process forming discrete electrodes on a current collector foil, where the tabs are notched into each respective discrete electrode in the appropriate positions along lateral edges.

FIGS. 9A-9Bshow components of another variation of a capacitor-assisted hybrid lithium-ion electrochemical cell assembly550prepared in accordance with certain aspects of the present disclosure having electrode components with tabs on two distinct, but adjoining edges. For brevity, unless otherwise specifically addressed, the components of the capacitor-assisted hybrid lithium-ion electrochemical cell assembly550having the same design, function, and/or dimensions as those in the capacitor-assisted hybrid lithium-ion electrochemical cell assembly150inFIGS. 4A-4Bpreviously described will not be described again in detail, but will be understood to share the same properties and dimensions as discussed above.

A first positive electrode560includes two edges562with a first length and two edges564with a second length, which may be greater than the first length. Notably, each of the edge562with the first length is adjoining or adjacent to an edge564with a second length, meaning that they connect at edge corners. The first positive electrode560has a first electrically conductive tab566on edge562with the first length. Further, the first positive electrode560has a second electrically conductive tab567on edge564with the second length. Thus, the first and second electrically conductive tabs566,567are disposed on two of four adjoining lateral edges of the first positive electrode560, so that two other adjoining lateral edges562,564are free of any tabs. Tab566is positioned at a location corresponding to a first side568of the respective edge562. Tab567is centrally positioned on edge564, but leaves terminal ends of the edge564near corners569unoccupied.

Tab566occupies less than half of the length of an edge562of the first positive electrode560, for example, a tab width may be greater than or equal to about 20% to less than or equal to about 45% of an overall length of the edge. In certain aspects, a height of the tab566may be greater than or equal to about 5 mm to less than or equal to about 30 mm. In certain other aspects, a width of the tab566may be greater than or equal to about 30 mm to less than or equal to about 300 mm. Each tab567occupies more than half an overall length of edge564, for example, a tab567length may be greater than or equal to about 50% to less than or equal to about 90% of an overall length of the edge. In certain aspects, a height of the tab567may be greater than or equal to about 5 mm to less than or equal to about 30 mm. In certain other aspects, a width of the tab567may be greater than or equal to about 50 mm to less than or equal to about 600 mm. Thus, tab566can be considered to be a small tab for lower power applications, while tab567can be considered to be a large tab for high power applications. Tabs566and567may vary in dimensions and shape from those shown inFIGS. 9A and 9B.

Also shown is a second positive electrode570that may comprise a distinct active material from the first positive electrode560. The second positive electrode570includes two edges572with a first length and two edges574with a second length, which may be greater than the first length. Notably, each of the edge572with the first length is adjoining or adjacent to an edge574with a second length, meaning that they connect or adjoin at edge corners. The second positive electrode570has a first electrically conductive tab576on edge572with the first length. Further, the second positive electrode570has a second electrically conductive tab567on edge574with the second length. Thus, the first and second electrically conductive tabs576,577are disposed on two of four adjoining lateral edges of the second positive electrode570, so that two other adjoining lateral edges572,574are free of any tabs. Tab576is positioned at a location corresponding to a first side578of the respective edge572. Tab577is centrally positioned on edge574, but leaves terminal ends of the edge574near corners579unoccupied. Tabs576and577may have the same sizing and dimensions as tabs566and567in first positive electrode560and for brevity will not be described again herein.

A separator580is included. A third negative electrode590includes two edges592with a first length and two edges594with a second length, which may be greater than the first length. Notably, each of the edge592with the first length is adjoining or adjacent to an edge594with a second length, meaning that they connect or adjoin at edge corners. The third negative electrode590has a first electrically conductive tab596on edge592with the first length. Further, the third negative electrode590has a second electrically conductive tab597on edge594with the second length. Thus, the first and second electrically conductive tabs596,597are disposed on two of four adjoining lateral edges of the third negative electrode590, so that two other adjoining lateral edges592,594are free of any tabs. Tab596is positioned at a location corresponding to a first side598of the respective edge592. Tab597is centrally positioned on edge594, but leaves terminal ends of the edge594near corners599unoccupied. While the positioning may be on distinct regions of the edge, tabs596and597may have the same sizing and dimensions as tabs566and567in first positive electrode560and for brevity will not be described again herein.

A fourth negative electrode600may comprise a distinct active material from the third negative electrode590. The fourth negative electrode600includes two edges602with a first length and two edges604with a second length optionally greater than the first length. Each of the edge602with the first length is adjoining or adjacent to an edge604with a second length, meaning that they connect or adjoin at edge corners. The fourth negative electrode600has a first electrically conductive tab606on edge602with the first length. Further, the fourth negative electrode600has a second electrically conductive tab607on edge604with the second length. Thus, the first and second electrically conductive tabs606,607are disposed on two of four adjoining lateral edges of the electrode600, so that two other adjoining lateral edges602,604are free of any tabs. Tab606is positioned at a location corresponding to a first side608of the respective edge602. Tab607is centrally positioned on edge604, but leaves terminal ends of the edge604near corners609unoccupied. While the positioning may be on distinct regions of the edge, again tabs606and607may have the same sizing and dimensions as tabs566and567in first positive electrode560and for brevity will not be described again herein.

The first positive electrode560, the second positive electrode570, the separator580, the third negative electrode590, and the fourth negative electrode600are then stacked together to form a core cell assembly610. In the core assembly610, edges612having the first length define a position at a first side614and a position at a second side616. The first side614corresponds to the first side568of first positive electrode560and first side578of the second positive electrode570. The plurality of the first electrically conductive tabs566of the first positive electrode560substantially align with the plurality of second electrically conductive tabs576of the second positive electrode570on the first side614when they are assembled together (e.g., stacked) and thus form a first common positive tab618. Similarly, edges613having the second length include the second electrically conductive tabs567of the first positive electrode560that substantially align with the plurality of second electrically conductive tabs577of the second positive electrode570on the first side614when they are assembled together (e.g., stacked) and thus form a second common positive tab619on one edge613.

The edge612having the first common positive tab618also has a first common negative tab620. The first common negative tab620is formed by substantially aligning the plurality of third electrically conductive tabs596of the third negative electrode590with the plurality of fourth electrically conductive tabs606of the fourth negative electrode600. Likewise, one edge613having the second length includes a second common negative tab621. The second common negative tab621is formed by substantially aligning the third electrically conductive tabs597of the third negative electrode590with the fourth electrically conductive tab607of the fourth negative electrode600when they are assembled together (e.g., stacked).

The core cell assembly610then is incorporated into and forms the capacitor-assisted hybrid lithium-ion electrochemical cell assembly550. The respective layers within the first common positive tab618may be welded together and appropriately capped or sheathed to form a first positive electrical connector630. Likewise, the second common positive tab619layers may be welded together and appropriately capped or sheathed to form a second positive electrical connector631. The positive electrical connectors630,631may be connected to other electrical conduits with the same polarity, such as bus bars, circuitry, or may themselves form terminals for external connection to loads, generators, or power sources and the like. Similarly, the first common negative tabs620may be welded together and appropriately capped or sheathed to form a first negative electrical connector632. Likewise, the second common negative tab621layers may be welded together and appropriately capped or sheathed to form a second negative electrical connector633. The negative electrical connectors632,633may be connected to other electrical conduits with the same polarity, such as bus bars, circuitry, or may themselves form terminals for external connection to loads, generators, or power sources and the like. The capacitor-assisted hybrid lithium-ion electrochemical cell assembly550can be incorporated into other components, such as a housing or pouch640prior to or after forming the positive electrical connectors630,631and negative electrical connectors632,633.

One lateral edge634of the four edges of the capacitor-assisted hybrid lithium-ion electrochemical cell assembly550has both the positive electrical connector630and a spaced apart negative electrical connector632(corresponding to the first side614and second side616of each lateral edge612). Additionally, two parallel edges636that are respectively adjoining to the lateral edge634have either the positive electrical connectors631or the negative electrical connector633. Further, opposing lateral edges634is free of any tabs. As shown, positive electrical connector630and negative electrical connector632on lateral edge634are relatively small electrical connectors suitable for low power applications, while the positive electrical connectors631or the negative electrical connector633on sides636are of a relatively large size for higher power applications.

By including four tabs integrally formed with and connected to positive or negative electrical connectors on four lateral edges of the electrochemical cell assembly, current and current density carried by any one of the tabs are minimized, which is particularly advantageous for ultra-high power applications. This in turns serves to reduce hot spots and diminish thermal gradients during high power charge and discharge conditions.

The capacitor-assisted hybrid lithium-ion electrochemical cell assembly550may be formed by an intermittent coating process forming discrete electrodes on a current collector foil, where the tabs are notched into each respective discrete electrode in the appropriate positions along lateral edges.

FIGS. 10A-10Bshow components of another variation of a capacitor-assisted hybrid lithium-ion electrochemical cell assembly650prepared in accordance with certain aspects of the present disclosure having electrode components with tabs continuous L-shaped tabs on two adjoining edges. Again, unless otherwise specifically addressed, the components of the capacitor-assisted hybrid lithium-ion electrochemical cell assembly650having the same design, function, and/or dimensions as those in the capacitor-assisted hybrid lithium-ion electrochemical cell assembly150inFIGS. 4A-4Bpreviously described will not be described again in detail, but will be understood to share the same properties and dimensions as discussed above.

A first positive electrode660includes two edges662with a first length and two edges664with a second length, which may be greater than the first length. Notably, each of the edges662with the first length is adjoining or adjacent to an edge664with a second length, meaning that they are physically connected to one another at edge corners. The first positive electrode660thus has a first electrically conductive tab666that is L-shaped and extends along one first edge662with the first length and one second edge664. Tab666occupies a majority or all of the length of both edge662and edge664, for example, an overall tab length for the L-shaped may be greater than or equal to about 60% to less than or equal to about 100% of an overall cumulative length of the both edge662and664. In certain variations, a width of the L-shaped tab666is co-extensive with a length of edge662and edge664. In certain aspects, a height652of the tab666may be greater than or equal to about 5 mm to less than or equal to about 30 mm. In certain other aspects, a width654of the tab666(as it extends over adjoining edges662,664) may be greater than or equal to about 50 mm to less than or equal to about 600 mm. A remaining first edge662and second edge664do not have any tabs.

Also shown is a second positive electrode670that may comprise a distinct active material from the first positive electrode660. The second positive electrode670includes two edges672with a first length and two edges674with a second length, which may be greater than the first length. Notably, each of the edges672with the first length is adjoining or adjacent to an edge674with a second length, meaning that they are physically connected at edge corners. The second positive electrode670has a second electrically conductive tab676that is L-shaped and extends along one first edge672with the first length and one second edge674. Tab676occupies a majority or all of the length of both edge672and edge674in a similar manner to tab666described in the context of the first positive electrode660and may have the same dimensions. Remaining first edge672and second edge674do not have any tabs.

A separator680is included. A third negative electrode690includes two edges692with a first length and two edges694with a second length, which may be greater than the first length. Edges692with the first length are adjoining or adjacent to edges694with a second length, meaning that they connect or adjoin at edge corners. The third negative electrode690has a third electrically conductive tab696that is L-shaped and extends along one first edge692with the first length and one second edge694. Tab696occupies a majority or all of the length of both edge692and edge694in a similar manner to tab666and have the same dimensions as described in the context of the first positive electrode660. However, third electrically conductive tab696is disposed on an opposite side and thus opposite edges of the electrode as compared to placement of tab666in first positive electrode660. Remaining first edge692and second edge694do not have any tabs. Again, the edges free of tabs in the third negative electrode690are in diametrically opposite positions to the edges free of tabs in the first and second positive electrodes660,670.

A fourth negative electrode700may have a distinct active material from the third negative electrode690. The fourth negative electrode700includes two edges702with a first length and two edges704with a second length, which may be greater than the first length. Edges702with the first length are adjoining or adjacent to edges704with a second length, meaning that they connect or adjoin at edge corners. The fourth negative electrode700has a fourth electrically conductive tab706that is L-shaped and extends along one first edge702with the first length and one second edge704. Tab706occupies a majority or all of the length of both edge702and edge704in a similar manner to tab666described in the context of the first positive electrode660. However, fourth electrically conductive tab706is disposed on an opposite side and thus opposite edges of the electrode as compared to placement of tab666in first positive electrode660. Remaining first edge702and second edge704do not have any tabs. Again, the edges free of tabs in the fourth negative electrode700are in diametrically opposite positions to the edges free of tabs in the first and second positive electrodes660,670.

The first positive electrode660, the second positive electrode670, the separator680, the third negative electrode690, and the fourth negative electrode700are then stacked together to form a core cell assembly710. In the core assembly710, the first electrically conductive L-shaped tab666of the first positive electrode660substantially aligns with the second electrically conductive L-shaped tab676of the second positive electrode670on a first side612of the core cell assembly710when they are assembled together (e.g., stacked). Similarly, on a second side714of the core cell assembly710diametrically opposed to the first side712, the third electrically conductive L-shaped tab696of the third negative electrode690substantially aligns with the fourth electrically conductive L-shaped tab706of the second positive electrode700. As shown, a common positive tab718is formed on adjoining edges713from a portion of the joined first electrically conductive L-shaped tab666and the second electrically conductive L-shaped tab676. Further, two distinct common negative tabs720are formed on adjoining edges715from a portion of the joined third electrically conductive L-shaped tab696and the fourth electrically conductive L-shaped tab706.

The core cell assembly710then is incorporated into and forms the capacitor-assisted hybrid lithium-ion electrochemical cell assembly650. Select regions of respective layers within the first common positive tab718may be welded in select regions and appropriately capped or sheathed to form a plurality of positive electrical connectors730. The positive electrical connectors730may be connected to other electrical conduits with the same polarity, such as bus bars, circuitry, or may themselves form terminals for external connection to loads, generators, or power sources and the like. Similarly, the first common negative tab720may be welded together in select regions and appropriately capped or sheathed to form a plurality of negative electrical connectors732. The negative electrical connector732may be connected to other electrical conduits with the same polarity, such as bus bars, circuitry, or may themselves form terminals for external connection to loads, generators, or power sources and the like. The capacitor-assisted hybrid lithium-ion electrochemical cell assembly650can be incorporated into other components, such as a housing or pouch740prior to or after forming the positive electrical connectors730and negative electrical connectors732.

As shown in the design inFIGS. 10A-10B, four large tabs that are asymmetric are included for enhanced current distribution. Further, using intermittent coated electrodes and large areas of foil in the form of tabs can provide lower cell resistance and better thermal distribution. Thus, a capacitor-assisted hybrid lithium-ion electrochemical cell assembly650has a plurality of positive electrical connectors and a plurality of negative electrical connectors, where a first edge has a positive electrical connector, an adjoining second edge has a negative electrical connector, a third edge has negative electrical connector, and a fourth edge has a positive electrical connector. In this design, a first pair of opposite edges have a positive electrical connector and a negative electrical connector. Further, a second pair of opposite edges also have a positive electrical connector and an opposite negative electrical connector. By including four tabs integrally formed with and connected to positive or negative electrical connectors on four lateral edges of the electrochemical cell assembly, current and current density carried by any one of the tabs are minimized, which is particularly advantageous for ultra-high power applications. This in turns serves to reduce hot spots and diminish thermal gradients during high power charge and discharge conditions.

The capacitor-assisted hybrid lithium-ion electrochemical cell assembly650may be formed by an intermittent coating process forming discrete electrodes on a current collector foil, where the tabs are notched into each respective discrete electrode in the appropriate positions along lateral edges.

FIGS. 11A-11Bshow components of a capacitor-assisted hybrid lithium-ion electrochemical cell assembly750prepared in accordance with certain aspects of the present disclosure having positive electrode components with tabs on two distinct opposing edges and negative electrode components with tabs on two distinct opposing edges.

A first positive electrode760includes two edges762with a first length and two edges764with a second length, which may be greater than the first length. A plurality of first electrically conductive tabs766extend along the edges764. Tabs766occupies a majority or all of the length of edge764, for example, an overall tab length for the tab may be greater than or equal to about 50% to less than or equal to about 100% of an overall cumulative length of the edge764. Remaining first edges762do not have any tabs.

Also shown is a second positive electrode770that may comprise a distinct active material from the first positive electrode760. The second positive electrode770includes two edges772with a first length and two edges774with a second length, which may be greater than the first length. A plurality of second electrically conductive tabs776extend along the edges774, like tab766above. Remaining first edges772do not have any tabs.

A separator780is included. A third negative electrode790includes two edges792with a first length and two edges794with a second length, which may be greater than the first length. A plurality of third electrically conductive tabs796extend along the edges792and have dimensions similar to tab766described above. Remaining first edges794do not have any tabs.

A fourth negative electrode800includes two edges802with a first length and two edges804with a second length, which may be greater than the first length. A plurality of fourth electrically conductive tabs806extend along the edges802and have dimensions similar to tab766described above. Remaining first edges804do not have any tabs.

The first positive electrode760, the second positive electrode770, the separator780, the third negative electrode790, and the fourth negative electrode800are then stacked together to form a core cell assembly810. In the core assembly810, the plurality of the first electrically conductive tabs766of the first positive electrode760substantially align with the plurality of second electrically conductive tabs776of the second positive electrode770when they are assembled together (e.g., stacked) and thus form first common positive tabs818. Similarly, common negative tabs820are formed by substantially aligning the third electrically conductive tabs796of the third negative electrode790with the fourth electrically conductive tab806of the fourth negative electrode800when they are assembled together (e.g., stacked).

The core cell assembly810then is incorporated into and forms the capacitor-assisted hybrid lithium-ion electrochemical cell assembly750. The respective layers within the common positive tabs818may be welded together and appropriately capped or sheathed to form a first positive electrical connector830. The positive electrical connectors630may be connected to other electrical conduits with the same polarity, such as bus bars, circuitry, or may themselves form terminals for external connection to loads, generators, or power sources and the like. Similarly, the common negative tabs820may be welded together and appropriately capped or sheathed to form a first negative electrical connector832. The negative electrical connectors832may be connected to other electrical conduits with the same polarity, such as bus bars, circuitry, or may themselves form terminals for external connection to loads, generators, or power sources and the like. The capacitor-assisted hybrid lithium-ion electrochemical cell assembly750can be incorporated into other components, such as a housing or pouch840prior to or after forming the positive electrical connectors830and negative electrical connectors832.

Each lateral edge834of the four edges of the capacitor-assisted hybrid lithium-ion electrochemical cell assembly750has either the positive electrical connector830or negative electrical connector832. Thus, a first pair is defined by one positive electrical connector830diametrically opposed by one negative electrical connector, while a second pair is also defined by a different positive electrical connector830diametrically opposed to a different negative electrical connector830. The capacitor-assisted hybrid lithium-ion electrochemical cell assembly750has a first edge with a positive electrical connector, an adjoining second edge with a negative electrical connector, a third edge with a positive electrical connector, and a fourth edge with a negative electrical connector, so that a first pair of opposite edges have a positive electrical connector and an opposite positive electrical connector and a second pair of opposite edges also have a negative electrical connector and an opposite negative electrical connector. By including four large tabs integrally formed with and connected to positive or negative electrical connectors disposed on four lateral and opposing edges of the electrochemical cell assembly, current and current density carried by any one of the tabs are minimized, which is particularly advantageous for ultra-high power applications. This in turns serves to reduce hot spots and diminish thermal gradients during high power charge and discharge conditions.

The capacitor-assisted hybrid lithium-ion electrochemical cell assembly750may be formed by an intermittent coating process forming discrete electrodes on a current collector foil, where the tabs are notched into each respective discrete electrode in the appropriate positions along lateral edges.

FIGS. 12A-12Bshow components of a capacitor-assisted hybrid lithium-ion electrochemical cell assembly850prepared in accordance with certain aspects of the present disclosure having positive electrode components with tabs on two distinct opposing edges and negative electrode components with tabs on one edge. The first positive electrode860includes two edges862with a first length and two edges864with a second length, which may be greater than the first length. A plurality of first electrically conductive tabs866extend along the edges864. Tabs866occupy a majority or all of the length of edge864, for example, an overall tab length for the tab may be greater than or equal to about 50% to less than or equal to about 100% of an overall cumulative length of the edge864. In certain aspects, a height of the tab866may be greater than or equal to about 5 mm to less than or equal to about 30 mm. In certain other aspects, a width of the tab866may be greater than or equal to about 50 mm to less than or equal to about 600 mm. Remaining first edges862do not have any tabs.

Also shown is a second positive electrode870that may comprise a distinct active material from the first positive electrode860. The second positive electrode870includes two edges872with a first length and two edges874with a second length, which may be greater than the first length. A plurality of second electrically conductive tabs876extend along the edges874, like tab866above and may share the same dimensions. Remaining first edges872do not have any tabs.

A separator780is included. A third negative electrode890includes two edges892with a first length and two edges894with a second length, which may be greater than the first length. A third electrically conductive tab896extends along the edge892and has dimensions similar to tab866described above. The other edge892and edges894do not have any tabs.

A fourth negative electrode900includes two edges902with a first length and two edges904with a second length, which may be greater than the first length. A fourth electrically conductive tab906extends along one edge902and has dimensions similar to tab866described above. The other edge902and edges904do not have any tabs.

The first positive electrode860, the second positive electrode870, the separator880, the third negative electrode890, and the fourth negative electrode900are then stacked together to form a core cell assembly910. In the core assembly910, the plurality of the first electrically conductive tabs866of the first positive electrode860substantially align with the plurality of second electrically conductive tabs876of the second positive electrode870when they are assembled together (e.g., stacked) and thus form first common positive tabs918. Similarly, a common negative tab920is formed by substantially aligning the third electrically conductive tab896of the third negative electrode890with the fourth electrically conductive tab906of the fourth negative electrode900when they are assembled together (e.g., stacked).

The core cell assembly910then is incorporated into and forms the capacitor-assisted hybrid lithium-ion electrochemical cell assembly850. The respective layers within the common positive tabs918may be welded together and appropriately capped or sheathed to form a first positive electrical connector930. The positive electrical connectors930may be connected to other electrical conduits with the same polarity, such as bus bars, circuitry, or may themselves form terminals for external connection to loads, generators, or power sources and the like. Similarly, the common negative tabs920may be welded together and appropriately capped or sheathed to form a first negative electrical connector932. The negative electrical connectors932may be connected to other electrical conduits with the same polarity, such as bus bars, circuitry, or may themselves form terminals for external connection to loads, generators, or power sources and the like. The capacitor-assisted hybrid lithium-ion electrochemical cell assembly850can be incorporated into other components, such as a housing or pouch940prior to or after forming the positive electrical connectors930and negative electrical connectors932.

Three lateral edges934of the four edges of the capacitor-assisted hybrid lithium-ion electrochemical cell assembly850has either the positive electrical connector930or negative electrical connector932. The capacitor-assisted hybrid lithium-ion electrochemical cell assembly850has a first edge936with a positive electrical connector930, an adjoining second edge938with a negative electrical connector932, a third edge940with a positive electrical connector930. A remaining edge is free of any electrical connectors. By including two positive electrical connectors and one negative electrical connector, this electrochemical cell assembly design decreases internal positive terminal temperatures and thermal gradients. This may be particularly advantageous in design where one of the positive electrodes includes a capacitor active material.

The capacitor-assisted hybrid lithium-ion electrochemical cell assembly850may be formed by a continuous electrode coating process where tabs can be created on one or two sides of a continuously deposited electrode that is intermittently cut at appropriate intervals. Alternatively, the capacitor-assisted hybrid lithium-ion electrochemical cell assembly850may be formed by an intermittent coating process forming discrete electrodes on a current collector foil, where the tabs are notched into each respective discrete electrode in the appropriate positions along lateral edges.

FIGS. 13A-13Bshow components of a capacitor-assisted hybrid lithium-ion electrochemical cell assembly950prepared in accordance with certain aspects of the present disclosure having positive electrode components with a tab on one edge and negative electrode components with tabs on two distinct opposing edges.

A first positive electrode960includes two edges962with a first length and two edges964with a second length, which may be greater than the first length. A first electrically conductive tab966extends along the edge962. The other edge892and edges894do not have any tabs. Tab966occupies a majority or all of the length of edge964, for example, an overall tab length for the tab may be greater than or equal to about 50% to less than or equal to about 100% of an overall cumulative length of the edge964. Tab966may have the same dimensions as tab866described above in the context of first positive electrode860inFIG. 12A.

Also shown is a second positive electrode970that may comprise a distinct active material from the first positive electrode960. The second positive electrode970includes two edges972with a first length and two edges974with a second length, which may be greater than the first length. A second electrically conductive tab976extends along the edge972, which may have the same dimensions as tab966.

A separator780is included. The third negative electrode990includes two edges992with a first length and two edges994with a second length, which may be greater than the first length. A plurality of third electrically conductive tabs996extend along the edges992, which may have the same dimensions as tab966. Remaining first edges994do not have any tabs.

A fourth negative electrode1000includes two edges1002with a first length and two edges1004with a second length, which may be greater than the first length. A plurality of fourth electrically conductive tabs1006extend along the edges1002, which may have the same dimensions as tab966. Remaining first edges1004do not have any tabs.

A core cell assembly1010is formed by assembling the first positive electrode960, the second positive electrode970, the separator980, the third negative electrode990, and the fourth negative electrode1000together. In the core assembly1010, the first electrically conductive tab966of the first positive electrode960substantially aligns with the second electrically conductive tab976of the second positive electrode970when they are assembled together (e.g., stacked) and thus form first common positive tabs1018. Similarly, common negative tabs1020are formed by substantially aligning the third electrically conductive tabs996of the third negative electrode990with the fourth electrically conductive tabs1006of the fourth negative electrode1000when they are assembled together (e.g., stacked).

The core cell assembly1010is incorporated into and forms the capacitor-assisted hybrid lithium-ion electrochemical cell assembly950. The respective layers within the common positive tab1018may be welded together and appropriately capped or sheathed to form a first positive electrical connector1030. The positive electrical connectors1030may be connected to other electrical conduits with the same polarity, such as bus bars, circuitry, or may themselves form terminals for external connection to loads, generators, or power sources and the like. Similarly, the common negative tabs1020may be welded together and appropriately capped or sheathed to form a first negative electrical connector1032. The negative electrical connectors1032may be connected to other electrical conduits with the same polarity, such as bus bars, circuitry, or may themselves form terminals for external connection to loads, generators, or power sources and the like. The capacitor-assisted hybrid lithium-ion electrochemical cell assembly950can be incorporated into other components, such as a housing or pouch1040prior to or after forming the positive electrical connectors1030and negative electrical connectors1032.

Three lateral edges of the four edges of the capacitor-assisted hybrid lithium-ion electrochemical cell assembly950has either the positive electrical connector1030or negative electrical connectors1032. The capacitor-assisted hybrid lithium-ion electrochemical cell assembly950has a first edge1036with negative electrical connector1032, an adjoining second edge1038with a positive electrical connector1030, a third edge1040with a negative electrical connector1032. A remaining edge1042is free of any electrical connectors. By including one positive electrical connectors and two negative electrical connectors, this electrochemical cell assembly design decreases internal negative terminal temperatures and thermal gradients. This may be particularly advantageous in design where one of the negative electrodes includes a capacitor active material.

The capacitor-assisted hybrid lithium-ion electrochemical cell assembly950may be formed by a continuous electrode coating process where tabs can be created on one or two sides of a continuously deposited electrode that is intermittently cut at appropriate intervals. Alternatively, the capacitor-assisted hybrid lithium-ion electrochemical cell assembly950may be formed by an intermittent coating process forming discrete electrodes on a current collector foil, where the tabs are notched into each respective discrete electrode in the appropriate positions along lateral edges.

FIGS. 14A-14Bshow components of a prismatic lithium-ion capacitor-assisted hybrid lithium-ion electrochemical cell assembly1050prepared in accordance with certain aspects of the present disclosure having with continuous L-shaped tabs on two adjoining edges of the positive electrode components and with continuous L-shaped tabs on two adjoining edges of the negative electrode components.FIG. 14Bshows assembly of the stack of component inFIG. 14Bto form a battery core having a pair of opposite edges have a positive electrical connector and an opposite negative electrical connector, along with cooling foils on edges not having the positive or negative electrical connector.FIGS. 14A-14Bhave a similar design to the capacitor-assisted hybrid lithium-ion electrochemical cell assembly650described inFIGS. 10-10B. Again, unless otherwise specifically addressed, the components of the capacitor-assisted hybrid lithium-ion electrochemical cell assembly1050having the same design, function, and/or dimensions as those in the capacitor-assisted hybrid lithium-ion electrochemical cell assembly150inFIGS. 4A-4Bor in the capacitor-assisted hybrid lithium-ion electrochemical cell assembly650inFIGS. 10A-10Bpreviously described, will not be discussed again in detail, but will be understood to share the same properties and dimensions as discussed above.

A first positive electrode1060includes two edges1062with a first length and two edges1064with a second length, which may be greater than the first length. Notably, each of the edges1062with the first length is adjoining or adjacent to an edge1064with a second length, meaning that they are physically connected to one another at edge corners. The first positive electrode1060thus has a first electrically conductive tab1066that is L-shaped and extends along one first edge1062with the first length and one second edge1064. Tab1066occupies a majority or all of the length of both edge1062and edge1064, for example, an overall tab length for the L-shaped may be greater than or equal to about 50% to less than or equal to about 100% of an overall cumulative length of the both edge1062and1064. In certain variations, a length of the L-shaped tab1066is co-extensive with a length of edge1062and edge1064. A remaining first edge1062and second edge1064do not have any tabs.

Also shown is a second positive electrode1070that may comprise a distinct active material from the first positive electrode1060. The second positive electrode1070includes two edges1072with a first length and two edges1074with a second length, which may be greater than the first length. Notably, each of the edges1072with the first length is adjoining or adjacent to an edge1074with a second length, meaning that they are physically connected at edge corners. The positive electrode1070has a second electrically conductive tab1076that is L-shaped and extends along one first edge1072with the first length and one second edge1074. Tab1076occupies a majority or all of the length of both edge1072and edge1074in a similar manner to tab1066described in the context of the first positive electrode1060. Remaining first edge1072and second edge1074do not have any tabs.

A separator1080is included. A third electrode1090includes two edges1092with a first length and two edges1094with a second length, which may be greater than the first length. Edges1092with the first length are adjoining or adjacent to edges1094with a second length, meaning that they connect or adjoin at edge corners. The third negative electrode1090has a third electrically conductive tab1096that is L-shaped and extends along one first edge1092with the first length and one second edge1094. Tab1096occupies a majority or all of the length of both edge1092and edge1094in a similar manner to tab1066described in the context of the first positive electrode1060. However, third electrically conductive tab1096is disposed on an opposite side and thus opposite edges of the electrode as compared to placement of tab1066in first positive electrode1060, for example. Remaining first edge1092and second edge1094do not have any tabs. Again, the edges free of tabs in the third negative electrode1090are in diametrically opposite positions to the edges free of tabs in the first and second positive electrodes1060,1070.

A fourth negative electrode1100may have a distinct active material from the third negative electrode1090. The fourth negative electrode1100includes two edges1102with a first length and two edges1104with a second length, which may be greater than the first length. Edges1102with the first length are adjoining or adjacent to edges1104with a second length, meaning that they connect or adjoin at edge corners. The fourth negative electrode1100has a fourth electrically conductive tab1106that is L-shaped and extends along one first edge1102with the first length and one second edge1104. Tab1106occupies a majority or all of the length of both edge1102and edge1104in a similar manner to tab1066described in the context of the first positive electrode1060. However, fourth electrically conductive tab1106is disposed on an opposite side and thus opposite edges of the electrode as compared to placement of tab1066in first positive electrode1060. Remaining first edge1102and second edge1104do not have any tabs. Again, the edges free of tabs in the fourth negative electrode1100are in diametrically opposite positions to the edges free of tabs in the first and second positive electrodes1060,1070.

The first positive electrode1060, the second positive electrode1070, the separator1080, the third negative electrode1090, and the fourth negative electrode1100are then stacked together to form a core cell assembly1110. In the core assembly1110, the first electrically conductive L-shaped tab1066of the first positive electrode1060substantially aligns with the second electrically conductive L-shaped tab1076of the second positive electrode1070on a first side1012of the core cell assembly1110when they are assembled together (e.g., stacked). Similarly, on a second side1114of the core cell assembly1110diametrically opposed to the first side1112, the third electrically conductive L-shaped tab1096of the third negative electrode1090substantially aligns with the fourth electrically conductive L-shaped tab1106of the second positive electrode1100. As shown, a common positive tab1118is formed from the joined first electrically conductive L-shaped tab1066and the second electrically conductive L-shaped tab1076. Further, a common negative tab1120is formed from a portion of the joined third electrically conductive L-shaped tab1096and the fourth electrically conductive L-shaped tab1106.

The core cell assembly1110then is incorporated into and forms the capacitor-assisted hybrid lithium-ion electrochemical cell assembly1050. Select regions of respective layers within the first common positive tab1118may be welded in select regions and appropriately capped or sheathed to form a positive electrical connector1130. In regions1122where the respective layers forming the common positive tab1118are not welded together (i.e., regions external to the positive electrical connector1130), layers of foil can remain exposed and serve as cooling foil along the edges of the electrode. This provides for internal cooling within the electrochemical cell. The positive electrical connectors1130may be connected to other electrical conduits with the same polarity, such as bus bars, circuitry, or may themselves form terminals for external connection to loads, generators, or power sources and the like.

Similarly, the common negative tab1120may be welded together in select regions and appropriately capped or sheathed to form a negative electrical connector1132. In regions1124where the respective layers forming the common negative tab1120are not welded together (i.e., regions external to the positive electrical connector1132), layers of foil can remain exposed and serve as cooling foil along the edges of the electrode. This further provides for internal cooling within the electrochemical cell. The negative electrical connector1132may be connected to other electrical conduits with the same polarity, such as bus bars, circuitry, or may themselves form terminals for external connection to loads, generators, or power sources and the like. The capacitor-assisted hybrid lithium-ion electrochemical cell assembly1050can be incorporated into other components, such as a housing or pouch1140prior to or after forming the positive electrical connectors1130and negative electrical connectors1132.

Thus, the capacitor-assisted hybrid lithium-ion electrochemical cell assembly1050has a positive electrical connector and a negative electrical connector, disposed on opposite sides of the assembly1150. Further, using intermittent coated electrodes and large areas of foil in the form of tabs can provide lower cell resistance, cooling, and better thermal distribution.

The capacitor-assisted hybrid lithium-ion electrochemical cell assembly1050may be formed by an intermittent coating process forming discrete electrodes on a current collector foil, where the tabs are notched into each respective discrete electrode in the appropriate positions along lateral edges.

In various aspects, the present disclosure provides new electrode designs for ultra-high power hybrid electrochemical cells with uniform thermal distribution, which are especially suitable for capacitor-assisted batteries that improve cell power performance and durability. These designs enable oriented current flow. For example, by including more tabs, more pathways for electrons are created within each electrode, so electrons travel less distance through the electrode than in conventional designs.

In certain variations, each electrode in the electrochemical cell assembly may comprise at least one electrically conductive tab that protrudes from at least one edge of the electrode and thus defines a height of greater than or equal to about 5 mm to less than or equal to about 30 mm. In certain other aspects, a width of each tab protruding from an edge of each electrode may be greater than or equal to about 30 mm to less than or equal to about 600 mm, optionally greater than or equal to about 30 mm to less than or equal to about 300 mm or in other variations, optionally greater than or equal to about 50 mm to less than or equal to about 600 mm.

In certain aspects, any given electrode in the capacitor-assisted hybrid lithium-ion electrochemical cells may have a maximum current density of less than or equal to about 300 mA/cm2. For example, a maximum current density is less than or equal to about 300 mA/cm2for at least one of the first electrode, the second electrode, the third electrode, or the fourth electrode. In certain variations, each of the first electrode, the second electrode, the third electrode, and the fourth electrode has a maximum current density is less than or equal to about 300 mA/cm2. In certain variations, a maximum current density is less than or equal to about 250 mA/cm2, optionally less than or equal to about 200 mA/cm2, optionally less than or equal to about 150 mA/cm2, optionally less than or equal to about 100 mA/cm2, and in certain aspects, optionally less than or equal to about 90 mA/cm2. In certain aspects, a current density within a respective electrode within the electrochemical cell is between about 0 and less than or equal to about 90 mA/cm2. The higher the current (or current density), the larger the thermal gradient. Thus, minimizing the current density serves to favorably reduce thermal gradients.

As noted above, assisted hybrid lithium-ion electrochemical cells prepared in accordance with certain aspects of the present disclosure have a reduced current density compared to a conventional two tab design for a comparative capacitor-assisted hybrid lithium-ion electrochemical cell assembly with the same materials. For example, a maximum current density is decreased by greater than or equal to about 35%, optionally greater than or equal to about 40%, optionally greater than or equal to about 50%, optionally greater than or equal to about 55%, optionally greater than or equal to about 60%, optionally greater than or equal to about 65%, optionally greater than or equal to about 70%, and in certain variations, optionally greater than or equal to about 75%.

In certain other aspects, the hybrid lithium-ion electrochemical cell assemblies prepared in accordance with the present disclosure can provide enhanced thermal management, such as comparatively lower direct current resistance (DCR) and less heat generated. By way of example, where performance of a capacitor-assisted hybrid lithium-ion electrochemical cell assembly prepared in accordance with certain aspects of the present disclosure is compared to a conventional two tab design for a comparative capacitor-assisted hybrid lithium-ion electrochemical cell assembly with the same materials, an electron path within the electrodes is reduced, so that direct current resistance (DCR) is decreased by greater than or equal to about 10%, optionally greater than or equal to about 20%, optionally greater than or equal to about 30%, optionally greater than or equal to about 40%, and in certain variations, optionally greater than or equal to about 50%. The lower the DCR, the less heat generated (e.g., Q=I2Rt, where Q is heat, I is current, R is resistance, and t is time), leading to an electrochemical cell that requires less extensive and simpler thermal management. A reduction in maximum current density favorably reduces thermal gradients, which are affected by charge/discharge currents. Further, more uniform counter-fields of electromagnetic interference (EMI) can be achieved with electrochemical cells prepared in accordance with the present disclosure.

Ultra-high power hybrid electrochemical cells incorporating the electrode designs described in the present disclosure have a longer battery life. In certain variations, a lithium-ion electrochemical cells incorporating an inventive electrode design substantially maintain charge capacity (e.g., performs within a preselected range or other targeted high capacity use) for greater than or equal to about 5,000 hours of battery operation, optionally greater than or equal to about 8,000 hours of battery operation, and in certain aspects, greater than or equal to about 10,000 hours or longer of battery operation (active cycling).

In certain variations, the a lithium-ion electrochemical cells incorporating an inventive electrode design are capable of operating within 20% of target charge capacity for a duration of greater than or equal to about 2 years (including storage at ambient conditions and active cycling time), optionally greater than or equal to about 3 years, optionally greater than or equal to about 4 years, optionally greater than or equal to about 5 years, optionally greater than or equal to about 6 years, optionally greater than or equal to about 7 years, optionally greater than or equal to about 8 years, optionally greater than or equal to about 9 years, and in certain aspects, optionally greater than or equal to about 10 years.

In other variations, the lithium-ion electrochemical cells incorporating an inventive electrode design according to certain aspects of the present disclosure are capable of operating at less than or equal to about 30% change in a preselected target charge capacity (thus having a minimal charge capacity fade) for at least about 2,000 deep discharge cycles, optionally greater than or equal to about 4,000 deep discharge cycles, optionally greater than or equal to about 6,000 deep discharge cycles, optionally greater than or equal to about 8,000 deep discharge cycles, and in certain variations, optionally greater than or equal to about 10,000 deep discharge cycles.