PATENT DOCUMENT

Publication Number: US-10658632-B1
Application Number: US-201816117096-A
Country: US
Kind Code: B1

Title: Battery housings for accommodating swelling of electrode assemblies

Abstract:
Battery housings and batteries are presented for accommodating swelling of an electrode assembly. In one aspect, a battery includes an electrode assembly that includes a cathode and an anode. The battery also includes a receptacle that includes at least one feedthrough disposed through one or more sides of the receptacle. A lid is sealed to the receptacle. The receptacle, the at least one feedthrough, and the lid form a sealed volume in which the electrode assembly and an electrolyte are disposed. The lid is configured to displace from a first position to a second position in response to a swelling of the electrode assembly within the sealed volume. The receptacle is configured to strain less than the lid during the swelling of the electrode assembly. The second position of the lid may correspond to an expanded volume of the electrode assembly that is 15% greater than an initial volume.

Claims:
What is claimed is: 
     
       1. A battery, comprising:
 an electrode assembly comprising a cathode and an anode; 
 a receptacle comprising at least one feedthrough disposed through one or more sides of the receptacle; and 
 a lid sealed to the receptacle; 
 wherein the receptacle, the at least one feedthrough, and the lid form a sealed volume in which the electrode assembly and an electrolyte are disposed; 
 wherein the lid is configured to displace from a first position to a second position in response to a swelling of the electrode assembly within the sealed volume; and 
 wherein the receptacle is configured to strain less than the lid during the swelling of the electrode assembly. 
 
     
     
       2. The battery of  claim 1 , wherein the second position of the lid corresponds to an expanded volume of the electrode assembly that is 15% greater than an initial volume. 
     
     
       3. The battery of  claim 2 , wherein the electrode assembly and the lid are separated by a gap no greater than 15% of an initial thickness of the electrode assembly. 
     
     
       4. The battery of  claim 1 , wherein the lid defines an undulating section that expands from the first position to the second position. 
     
     
       5. The battery of  claim 1 , wherein the lid includes a flexible element to expand from the first position to the second position. 
     
     
       6. The battery of  claim 1  further comprising a seal between the lid and the receptacle. 
     
     
       7. The battery of  claim 1 , wherein the lid comprises a laminate comprising a metal layer and a polymer layer. 
     
     
       8. The battery of  claim 7 , wherein the metal layer comprises aluminum and the polymer layer comprises polypropylene. 
     
     
       9. The battery of  claim 1 , comprising a sealing compound disposed between the receptacle and the lid. 
     
     
       10. The battery of  claim 9  wherein the sealing compound comprises a polymer. 
     
     
       11. The battery of  claim 10 , wherein the polymer comprises polypropylene. 
     
     
       12. The battery of  claim 1 , wherein the receptacle is configured to strain no greater than 0.1% during the swelling of the electrode assembly. 
     
     
       13. The battery of  claim 1 , wherein the one or more sides of the receptacle each have an exterior surface and an interior surface connected by an edge. 
     
     
       14. The battery of  claim 13 , wherein a seal is formed between the lid and the edge of at least one side. 
     
     
       15. The battery of  claim 13 , wherein a seal is formed between the lid and the exterior surface of at least one side. 
     
     
       16. The battery of  claim 13 , wherein a seal is formed between the lid and the interior surface of at least one side.

Description:
PRIORITY 
     This application claims the benefit under 35 U.S.C. § 119(e) of U.S. Provisional Patent Application Ser. No. 62/562,842, entitled “BATTERY HOUSINGS FOR ACCOMMODATING SWELLING OF ELECTRODE ASSEMBLIES,” filed on Sep. 25, 2017, which is incorporated herein by reference in its entirety. 
    
    
     FIELD 
     This disclosure relates generally to housing for enclosing battery cells, and more particularly, to battery housing for accommodating swelling of electrode assemblies. 
     BACKGROUND 
     A battery stores and releases electrical energy by relying on the chemical diffusion of ions between an anode electrode and a cathode electrode. During storage of electrical energy, ions flow from the cathode electrode to the anode electrode in response to a voltage potential placed across the battery&#39;s terminals. Conversely, during release of electrical energy, ions flow from the anode electrode to the cathode electrode as the battery drives current through an electrical load battery. An electrolyte serves as a transport medium to facilitate chemical diffusion between the anode electrode and the cathode electrode. 
     The battery employs an electrode assembly to control chemical diffusion between the anode electrode and the cathode electrode. The electrode assembly includes a separator disposed between the anode electrode and the cathode electrode. The separator serves to isolate the anode electrode from the cathode electrode and provides a permeable matrix through which the electrolyte (and ions therein) can diffuse. However, repeated storage and release of electrical energy from the battery may induce the electrode assembly to irreversibly swell. Such swelling may be caused by chemical changes in the electrode assembly, the electrolyte, or both. Battery housings are desired that can accommodate swelling of an electrode assembly. 
     SUMMARY 
     In one aspect, a battery includes an electrode assembly that includes a cathode and an anode. The battery also includes a receptacle that includes at least one feedthrough disposed through one or more sides of the receptacle. A lid is sealed to the receptacle. The receptacle, the at least one feedthrough, and the lid form a sealed volume in which the electrode assembly and an electrolyte are disposed. The lid is configured to displace from a first position to a second position in response to a swelling of the electrode assembly within the sealed volume. The receptacle is configured to strain less than the lid during the swelling of the electrode assembly. The second position of the lid may correspond to an expanded volume of the electrode assembly that is 15% greater than an initial volume. In further embodiments, the electrode assembly and the lid are separated by a gap no greater than 15% of an initial thickness of the electrode assembly. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The disclosure will be readily understood by the following detailed description in conjunction with the accompanying drawings, wherein like reference numerals designate like structural elements, and in which: 
         FIG. 1A  is a perspective view is presented of a battery housing for accommodating swelling of an electrode assembly, according to an illustrative embodiment; 
         FIG. 1B  is a cross-sectional view of the battery housing of  FIG. 1A , according to an illustrative embodiment; 
         FIG. 1C  presents a cross-sectional view of the battery housing of  FIG. 1B , but in which a receptacle and a lid form a seal on an edge of a side wall, according to an illustrative embodiment; 
         FIG. 1D  is a cross-sectional view of the battery housing of  FIG. 1B , but in which a receptacle and a lid form a seal on an exterior surface of a side wall, according to an illustrative embodiment; 
         FIG. 1E  is a cross-sectional view of the battery housing of  FIG. 1B , but in which a receptacle and a lid form a seal on an interior surface of a side wall, according to an illustrative embodiment; 
         FIG. 1F  presents a cross-sectional view of the battery housing of  FIG. 1B , but in which a lid includes corners having radiuses, according to an illustrative embodiment; 
         FIG. 1G  presents a cross-sectional view of the battery housing of  FIG. 1B , but in which the lid  106  includes an undulation, according to an illustrative embodiment; 
         FIG. 1H  presents a cross-sectional view of the battery housing of  FIG. 1B , but in which the lid includes rigid portions and a flexible element proximate a seal, according to an illustrative embodiment; 
         FIG. 2A  presents a perspective view of a battery for accommodating swelling of an electrode assembly, according to an illustrative embodiment; 
         FIG. 2B  presents a cross-sectional view of the battery of  FIG. 2A , according to an illustrative embodiment. 
     
    
    
     DETAILED DESCRIPTION 
     A description of various embodiments will now be made with reference to the accompanying drawings. It should be understood that the following descriptions are not intended to limit the embodiments to one preferred embodiment. To the contrary, it is intended to cover alternatives, modifications, and equivalents as can be included within the spirit and scope of the described embodiments as defined by the appended claims. 
     An electrode assembly of a lithium-ion battery cell may swell in response to cycles of charging and discharging. Swelling of the electrode assembly may result from dimensional changes in the anode and cathode active materials of the electrode assembly. Such active materials are operable to store and release lithium ions via an electrochemical process that alters spacing within their crystalline structures. Swelling of the electrode assembly may also result from the decomposition of electrolyte in the electrode assembly. This decomposition may introduce new chemical species into the electrolyte, increasing its volume and possibly liberating gaseous species. Over an operational lifetime, the electrode assembly may expand by up to 20 percent relative to its initial volume. 
     Conventional battery housings are poorly suited to accommodate swelling of an electrode assembly. Conventional battery housings are commonly fabricated with rigid metal walls (e.g., a metal can), which constrain swelling of the electrode assembly. As a result, swelling of the electrode assembly induces high stresses within the rigid metal walls, placing such housings at risk for rupture. Moreover, swelling of the electrode assembly may cause layers thereof, i.e., layers associated with an anode electrode, a cathode electrode, and a separator, to shift and drag against the rigid metal walls. This shifting or dragging may create folds or wrinkles in the electrode assembly, perturbing its configuration and reducing its performance (e.g., reducing storage capacity over time). 
     To account for swelling of an electrode assembly enclosed within a battery housing, the battery housing may include “head space” (e.g., available and unoccupied volume). Head space, however, reduces packaging efficiency and decreases volumetric capacity of the battery. Incorporating head space in a battery housing, may therefore, be suboptimal. Alternatively, the battery housing may be manufactured from pliable materials (e.g., flexible pouch) that are configured to deform in response to swelling of the electrode assembly. Flexible pouches may expand in various directions, which may in turn compromise the integrity of the battery housing should it contact other components with sharp edges or corners. 
     The embodiments described herein relate to battery housings for accommodating swelling of an electrode assembly, and batteries employing such housings. Controlled expansion allows the electrode into an area of the battery that can accommodate the overflow. The battery housings include a lid sealed to a receptacle that allows controlled expansion of an electrode assembly during swelling. The receptacle includes at least one feedthrough disposed through one or more sides of the receptacle. The lid is configured to accommodate swelling of the electrode assembly, which in some embodiments, involves displacing from a first position to a second position. This displacement increases a sealed volume formed by the receptacle, the at least one feedthrough, and the lid. The electrode assembly and an electrolyte are disposed within the sealed volume. 
     As used herein, the term “electrode assembly” refers to an anode electrode (or anode) and a cathode electrode (or cathode) having a separator disposed therebetween. The anode electrode includes an anode current collector having an anode active material disposed thereon. The cathode electrode includes a cathode current collector having a cathode active material disposed thereon. The “electrode assembly” may include a stack of layers, i.e., layers associated with the anode current collector and corresponding anode active material, the cathode current collector and corresponding cathode active material, and the separator. The stack of layers may be in a planar configuration (e.g., flat) or may be wrapped into a wound configuration (e.g., a “jelly roll”). A conductive tab may be coupled to each of the anode electrode and the cathode electrode (or individual layers associated with the anode current collector or cathode current collector). 
     As used herein, the term “strain” refers to the dimensional change of a body in response to a stress (σ), pressure (P), or force (F). “Strain” (ε) may be quantified using a percent that is defined according to ε=(d f −d i )/d i *100%. Here, d f  corresponds to the magnitude of a dimension when the stress, pressure, or force is applied to the body; and d i  corresponds to the magnitude of the dimension when no stress, pressure or force is applied to the body. It will be recognized that d f −d i  represents the elongation (or contraction) of the dimension when the stress, pressure, or force is applied to the body. Non-limiting examples of the dimension include a width, a depth, and a height of a battery housing. Non-limiting examples of the stress, pressure, or force include those resulting from swelling of an electrode assembly within the battery housing. The battery housing may seal the electrode assembly therein. 
     Now referring to  FIG. 1A , a perspective view is presented of a battery housing  100  for accommodating swelling of an electrode assembly  102 , according to an illustrative embodiment.  FIG. 1B  presents a cross-sectional view of the battery housing  100  of  FIG. 1A , according to an illustrative embodiment. It will be understood that the battery housing  100  and electrode assembly  102  shown in  FIGS. 1A and 1B  may correspond to a battery, such as an alkaline battery, a zinc-carbon battery, a silver-zinc battery, a nickel-cadmium battery, a nickel-metal hydride battery, a lithium-ion battery, a lithium polymer battery, and so forth. 
     The battery housing  100  includes a receptacle  104  and a lid  106  that are collectively operable to enclose the electrode assembly  102 . The receptacle  104  may include a side wall  108  encircling an open space  110  for containing the electrode assembly  102 . The receptacle  104  also includes an orifice  112  disposed through the side wall  108  and configured to receive a feedthrough  114 , which may be an electrical feedthrough. Although  FIG. 1A  depicts the receptacle  104  as having only one feedthrough  114 , this depiction is not intended as limiting. The receptacle  104  may include at least one feedthrough disposed through one or more sides (or walls) of the receptacle  104 . 
     A base wall  116  may connect portions of the side wall  108  to define a bottom surface for the battery housing  100 . The lid  106  is configured to cover the open space  110  and couple to the receptacle  104  through a seal  118 . The seal  118 , which may be a hermetic seal, is formed on the side wall  108  around the open space  110 . 
     It will be appreciated that the lid  106  is sealed to the receptacle  104 . As such, the receptacle, the feedthrough  114 , and the lid  106  form a sealed volume in which the electrical assembly  102  and an electrolyte are disposed. A portion of the electrode assembly  102  may protrude out of the open space  110  and into a pocket  120  of the lid  106 , as shown in  FIGS. 1A &amp; 1B . However, in other embodiments, the electrode assembly  102  is contained entirely within the open space  110  of the receptacle  104 . For example, and without limitation, an outermost surface of the electrode assembly  102  (i.e., relative to the base wall  116 ) may be level with a distal surface of the side wall  108 . Alternatively, the outermost surface of the electrode assembly  102  may be below the distal surface of the side wall  108 . In such alternative embodiments, the lid  106  (or portions thereof) may extend into the open space  110 . 
     The seal  118  may involve direct coupling of the lid  106  to the receptacle  104  (e.g., a friction fit), or in some variations, may employ a sealing compound to allow (or improve) such coupling. The sealing compound may be disposed between the receptacle  104  and the lid  106 . Non-limiting examples of the sealing compound include a soldering alloy, a brazing alloy, an adhesive, a glue, an epoxy, and a polymer (e.g., polypropylene). Other types of sealing compounds are possible. In some embodiments, the seal  118  includes a polymer disposed on the side wall  108 , which may be fusible. The polymer may allow the lid  106  to be coupled to the receptacle  104  via thermal, magnetic-pulse, or ultrasonic welding. Non-limiting examples of the polymer include polyethylene (PE), polypropylene (PP), polyethylene terephthalate (PET), and nylon (NL). The polymer may be in cast form, i.e., cast polyethylene (CPE), cast polypropylene (CPP), cast polyethylene terephthalate (CPET), and nylon (CNL). In some instances, the polymer includes polypropylene (or cast polypropylene). 
     It will be appreciated that the receptacle  104  and the lid  106  are configured such that swelling of the electrode assembly  102  displaces the lid  106  outward while leaving the receptacle  104  substantially unstrained, i.e., with a strain less than or equal to 0.1% (i.e., ε≤0.1%). In general, the receptacle  104  is configured to strain less than the lid during swelling of the electrode assembly  102 . Strains associated with the receptacle  104  and the lid  106  include those of width, depth, height, diameter, or radius. Other types strains are possible (e.g., shear, torsion, etc.). Accordingly, the walls of the receptacle  104  may be selected in material and thickness to resist pressure within the open space  110 , and the lid  106  may be selected in material and thickness to displace under such pressure. 
     In some embodiments, the receptacle  104  is formed of aluminum or an aluminum alloy. Non-limiting examples of the aluminum alloy include 1100 aluminum alloy, 6063 aluminum alloy, and 7075 aluminum alloy. In some embodiments, the receptacle  104  is formed of carbon steel. Non-limiting examples of carbon steel include low-carbon steel (i.e., up to 0.30% carbon by weight), medium-carbon steel (i.e., 0.3-0.6% carbon by weight), and high-carbon steel (i.e., 0.6-1.0% carbon by weight). In some embodiments, the receptacle  104  is formed of stainless steel. Non-limiting examples of the stainless steel include SS304, SS316L, and SS630. In some embodiments, the receptacle  104  is formed of titanium or a titanium alloy. Non-limiting examples of the titanium alloy include Grade 5 titanium alloy and Grade 7 titanium alloy. 
     It will be appreciated that the receptacle  104  may be formed of a composite material. For example, and without limitation, the receptacle  104  may include a first material, which serves as an inner wall, and a second material, which serves as an outer wall. The first material may be steel (e.g., carbon steel, stainless steel, etc.) and the second material may be aluminum or an aluminum alloy. In another non-limiting example, the receptacle  104  may include ceramic fibers, glass fibers, organic fibers, or any combination thereof disposed within a polymer matrix. The ceramic fibers may include silicon carbide fibers, aluminum oxide fibers, carbon or graphitic fibers, carbon nanotubes, and boron fibers. The glass fibers may include A-glass, C-glass, E-CR-glass, D-glass, S-glass, T-glass, silica fibers, quartz fibers, and quartz. The organic fibers may include aramid fibers and polyester fibers. Other compositions for the ceramic fibers, the glass fibers, and the organic fibers are possible. The polymer matrix may include polyester resins, vinyl ester resins, epoxy resins, phenolic resins, polyether ketone (PEEK), polyphenylene sulfide (PPS), polysulfone, polyetherimide (PEI), and polyamide-imide (PAI). Other compositions for the polymer matrix are possible. 
     The receptacle  104  may include a wall having a thickness ranging from 0.2 mm to 5.0 mm. In some embodiments, the receptacle  104  includes a wall having a thickness no greater than 5.0 mm. In some embodiments, the receptacle  104  includes a wall having a thickness no greater than 4.0 mm. In some embodiments, the receptacle  104  includes a wall having a thickness no greater than 3.0 mm. In some embodiments, the receptacle  104  includes a wall having a thickness no greater than 2.5 mm. In some embodiments, the receptacle  104  includes a wall having a thickness no greater than 2.0 mm. In some embodiments, the receptacle  104  includes a wall having a thickness no greater than 1.5 mm. In some embodiments, the receptacle  104  includes a wall having a thickness no greater than 1.0 mm. In some embodiments, the receptacle  104  includes a wall having a thickness no greater than 0.7 mm. In some embodiments, the receptacle  104  includes a wall having a thickness no greater than 0.5 mm. In some embodiments, the receptacle  104  includes a wall having a thickness no greater than 0.3 mm. 
     In some embodiments, the receptacle  104  includes a wall having a thickness no less than 0.2 mm. In some embodiments, the receptacle  104  includes a wall having a thickness no less than 0.3 mm. In some embodiments, the receptacle  104  includes a wall having a thickness no less than 0.5 mm. In some embodiments, the receptacle  104  includes a wall having a thickness no less than 0.7 mm. In some embodiments, the receptacle  104  includes a wall having a thickness no less than 1.0 mm. In some embodiments, the receptacle  104  includes a wall having a thickness no less than 1.5 mm. In some embodiments, the receptacle  104  includes a wall having a thickness no less than 2.0 mm. In some embodiments, the receptacle  104  includes a wall having a thickness no less than 2.5 mm. In some embodiments, the receptacle  104  includes a wall having a thickness no less than 3.0 mm. In some embodiments, the receptacle  104  includes a wall having a thickness no less than 4.0 mm. 
     It will be understood that the upper and lower limits may be combined in any variation as above to define a range for the thickness. For example, and without limitation, the receptacle  104  may include a wall having a thickness no greater than 4.0 mm but no less than 2.5 mm. In another non-limiting example, the receptacle  104  may include a wall having a thickness no greater than 0.7 mm but no less than 0.3 mm. Other ranges are possible. 
     In some embodiments, the lid  106  includes a laminate comprising a metal layer and a polymer layer. The metal layer may be bonded to a polymer layer. The laminate may be less than 500 μm in thickness. The metal layer may serve as a barrier to molecular diffusion, such as diffusion by water molecules, oxygen, and so forth. Non-limiting examples of the metal layer include a layer of aluminum or an aluminum alloy, stainless steel, carbon steel, and titanium or a titanium alloy. The metal layer may range in thickness from 1 μm to 10 μm. Non-limiting examples of the polymer layer include a layer of polyethylene (PE), a layer of polypropylene (PP), a layer of polyethylene terephthalate (PET), and a layer of nylon (NL). The polymer layer may range in thickness from 20 μm to 100 μm and may be in cast form (e.g., cast polyethylene, cast polypropylene, etc.). In certain instances, the metal layer includes aluminum and the polymer layer includes polypropylene (or cast polypropylene). In these instances, the metal layer may range from 3 μm to 5 μm in thickness and the polymer layer may range from 40 μm to 80 μm in thickness. 
     In further embodiments, the polymer layer is a first polymer layer and the metal layer has a second polymer layer bonded thereto and opposite the first polymer layer, i.e., the metal layer is sandwiched between the first polymer layer and the second polymer layer. Non-limiting examples of the second polymer layer include a layer of polyethylene (PE), a layer of polypropylene (PP), a layer of polyethylene terephthalate (PET), and a layer of nylon (NL). The second polymer layer may range in thickness from 20 μm to 100 μm and may be in cast form (e.g., cast polyethylene, cast polypropylene, etc.). In some instances, the lid  106  includes a laminate having a layer of aluminum sandwiched between two layers of polypropylene (or cast polypropylene), i.e., PP/Al/PP, PP/Al/CPP, and CPP/Al/CPP. 
     It will be understood that, in embodiments where the lid  106  includes the laminate, one or both of the first polymer layer and the second polymer layer may be a stack of polymer layers. In these embodiments, a first layer in the stack of polymer layers is bonded to the metal layer. Moreover, one or more polymer layers in the stack of polymer layers may be in cast form. For example, and without limitation, the stack of polymer layers may be PET/PP with PET being bonded to the metal layer (i.e., the first layer includes PET). In another non-limiting example, the stack of polymer layers may be CPP/CPE/CPET with CPP being bonded to the metal layer. In still yet another non-limiting example, the stack of polymer layers may be NL/PET/CPP with NL bonded to the metal layer. Representative examples of laminates include PP/PET/Al/PP, CPP/PET/Al/CPP, PET/Al/PP/PE/PET, PET/AL/CPP/CPE/CPET, PET/Al/NL/PET/PP, and PET/Al/NL/PET/CPP. Other variations are possible. 
     In some embodiments, the lid  106  includes a material forming the seal  118  with the receptacle  104 . For example, and without limitation, the lid  106  may include a polymer capable of fusing or adhering to the side wall  108  of the receptacle  104  (e.g., polypropylene). In another non-limiting example, the lid  106  may include a metal capable of being welded to the side wall  108  of the receptacle (e.g., aluminum). Other materials are possible. 
     In embodiments where the seal  118  includes the polymer disposed on the side wall  108 , the polymer layer of the laminate may match, in composition, the polymer disposed on the side wall  108 . For example, and without limitation, the polymer may include polypropylene and the polymer layer may also be polypropylene. One or both of the polymer and the polymer layer may be in cast form. If the polymer layer is a stack of polymer layers, the outermost layer may match the polymer in composition. For example, and without limitation, the polymer may include polypropylene (or cast polypropylene) and the polymer layer may be a stack of polymer layers corresponding to PET/Al/NL/PET/PP or PET/Al/NL/PET/CPP. Such matching may improve formation of the seal  118  during manufacturing and increase a strength of the seal  118 . 
     In some embodiments, an insulator  122  is disposed between the electrode assembly  102  and one or both of the receptacle  104  and the lid  106 . The insulator  122  is operable to electrically isolate the electrode assembly  102  from the receptacle  104 , the lid  106 , or both. The insulator  122  may be formed of a material having a dielectric strength of at least 10 kV/mm. In some instances, such as shown in  FIGS. 1A &amp; 1B , the insulator  122  may include a package enclosing the electrode assembly  102 . The package may be formed of polyethylene terephthalate (PET). In other instances, the insulator  122  is disposed over an inner surface of the receptacle  104 , the lid  106 , or both. The insulator  122  may cover the inner surface in its entirety or a portion thereof. 
     It will be appreciated that the battery housing  100  employs a hybrid construction that includes rigid and flexible portions, i.e., the receptacle  104  and the lid  106 , respectively. The hybrid construction allows the battery housing  100  to offer a spacious internal volume—greater than 10 mm in depth, if desired—while simultaneously accommodate swelling of the electrode assembly  102 . Moreover, the hybrid construction allows the battery housing  100  to be manufactured with rapid, cost-efficient processes such as drawing processes, stamping processes, and low-temperature (&lt;300° C.) welding. For example, and without limitation, the receptacle  104  may be deep drawn from a sheet of ductile material (e.g., a metal) such that the open space  110  has a depth of 10 mm or more. The lid  106 , when including the laminate, may be coupled to the receptacle  104  via thermal, magnetic-pulse welding, or ultrasonic welding. Other low-temperature processes are possible. 
     In contrast, conventional pouch-type battery housings are manufactured from laminates using drawing processes that are restricted to depths less than 10 mm. Laminates lack sufficient mechanical strength to allow the formation of deep pockets without tearing (i.e., pockets greater 10 mm in depth). Thus, unless expensive forming processes are used, conventional pouch-type battery housings are limited to electrode assemblies less than 10 mm in thickness. Although conventional metal-type battery housings can be used to overcome this limitation, conventional metal-type battery housings are rigid and thus are poorly suited to accommodate the swelling of electrode assemblies. The battery housing  100  described herein overcomes both of these disadvantages by virtue of its hybrid construction. The receptacle  104  allows the battery housing  100  to enclose electrode assemblies thicker than 10 mm, while the lid  106  allows the battery housing  100  to accommodate swelling of the electrode assembly  102  (e.g., via displacement, flexure, etc.). Moreover, the battery housing  100  can be configured to enclose a plurality of electrode assemblies. In these variations, the battery housing  100  may correspond to a battery pack. 
     In operation, the battery housing  100  encloses the electrode assembly  102  within an internal volume (or sealed volume) defined by the receptacle  104 , the lid  106 , and the feedthrough  114 . In particular, the electrode assembly  102  is seated within the open space  110 , which is bounded by the side wall  108  and the base wall  116 . The lid  106  is coupled to the receptacle  104  through the seal  118 , thereby closing off the open space  110 . The seal  118 , which may be a hermetic seal, is formed on the side wall  108  around the open space  110 . The seal  118  may include the polymer, which is disposed on the side wall  108 . During enclosure of the electrode assembly  102 , thermal, magnetic pulse, or ultrasonic welding may be used to form the seal  118  between the receptacle  104  and the lid  106 . The polymer, if present, may improve a quality of the seal  118 , such as a strength of the seal  118  and a leak rate of the seal  118 . 
     Cycles of charging and discharging may induce the electrode assembly  102  to swell. It will be appreciated that the lid  106  is configured to accommodate a swelling of the electrode assembly  102  up to 15% in volume. During the swelling of the electrode assembly  102 , the receptacle  104  is configured to strain less than the lid  106 . In many embodiments, the receptacle  104  is configured to strain no greater than 0.1% (i.e., ε≤0.1%) during swelling of the electrode assembly  102 . This strain may be measured along principal dimensions of the receptacle  104 . For rectangular embodiments, such as shown in  FIGS. 1A &amp; 1B , the principal directions may include a width, a depth, and a height of the receptacle  104 . For spherical or cylindrical embodiments, the principal dimensions may include a diameter or a radius. Other principal dimensions are possible, depending on a configuration of the receptacle  104 . 
     The receptacle  104  is operable to partially constrain the swelling of the electrode assembly  102  such that its expansion is directed towards the lid  106 . Thus, the receptacle  104  serves to help control expansion of the electrode assembly  102  within the battery housing  10  during swelling. Such may be along one or more predetermined directions.  FIGS. 1A &amp; 1B  depict the battery housing  100  as having a predetermined direction substantially perpendicular to the base wall  116  (see arrows  124 ) and out of the open space  110 . However, this depiction is for purposes of illustration only. The lid  106  displaces outward in response to swelling of the electrode assembly  102 . This displacement may, in certain instances, involve stretching or deformation of the lid  106 , i.e., strain, but without rupture. As such, the lid  106  may be configured to displace from a first position to a second position as the electrode assembly  102  swells, thereby increasing the internal volume (or sealed volume). The second position may correspond to a position of the lid  106 , beyond which, the structural integrity of the lid  106  may be compromised. 
     In some embodiments, the lid  106  displaces from the first position to the second position as the electrode assembly  102  swells from, respectively, an initial volume to an expanded volume. The initial volume may correspond to a volume of the electrode assembly  102  after being sealed within the battery housing  100 , but having experienced no more than 5 charge and discharge cycles. In some embodiments, the lid  106  displaces from the first position to the second position as the electrode assembly  102  swells from, respectively, an intermediate volume to the expanded volume. The intermediate volume may correspond to a volume of the electrode assembly  102  after first swelling from the initial volume to fill the pocket  120  of the lid  106 . 
     In some embodiments, the second position of the lid  106  corresponds to an expanded volume of the electrode assembly  102  that is 15% greater than an initial volume. In some embodiments, the second position of the lid  106  corresponds to an expanded volume of the electrode assembly  102  that is 12% greater than an initial volume. In some embodiments, the second position of the lid  106  corresponds to an expanded volume of the electrode assembly  102  that is 10% greater than an initial volume. In some embodiments, the second position of the lid  106  corresponds to an expanded volume of the electrode assembly  102  that is 8% greater than an initial volume. In some embodiments, the second position of the lid  106  corresponds to an expanded volume of the electrode assembly  102  that is 6% greater than an initial volume. In some embodiments, the second position of the lid  106  corresponds to an expanded volume of the electrode assembly  102  that is 4% greater than an initial volume. In some embodiments, the second position of the lid  106  corresponds to an expanded volume of the electrode assembly  102  that is 2% greater than an initial volume. 
     It will be understood that the initial, intermediate, and expanded volumes may be represented, respectfully, by initial, intermediate, and expanded thicknesses. For example, and without limitation, the second position of the lid  106  may correspond to an expanded thickness of the electrode assembly. 
     In some embodiments, the second position of the lid  106  corresponds to an expanded thickness of the electrode assembly  102  that is 15% greater than an initial thickness. In some embodiments, the second position of the lid  106  corresponds to an expanded thickness of the electrode assembly  102  that is 12% greater than an initial thickness. In some embodiments, the second position of the lid  106  corresponds to an expanded thickness of the electrode assembly  102  that is 10% greater than an initial thickness. In some embodiments, the second position of the lid  106  corresponds to an expanded thickness of the electrode assembly  102  that is 8% greater than an initial thickness. In some embodiments, the second position of the lid  106  corresponds to an expanded thickness of the electrode assembly  102  that is 6% greater than an initial thickness. In some embodiments, the second position of the lid  106  corresponds to an expanded thickness of the electrode assembly  102  that is 4% greater than an initial thickness. In some embodiments, the second position of the lid  106  corresponds to an expanded thickness of the electrode assembly  102  that is 2% greater than an initial thickness. 
     It will be appreciated that the seal  118  supports displacement of the lid  106  by maintaining coupling between the receptacle  104  and the lid  106 . Accordingly, in some embodiments, the seal  118  is configured with a strength to support pressure within the battery housing  100  caused by swelling of the electrode assembly  102 . Non-limiting examples of the strength include a tensile strength and a burst strength. The strength may be measured according to standards known to those skilled in the art (e.g., ASTM F88, ASTM F1140, ASTM F2054, etc.). 
     In some embodiments, the seal  118  has a burst strength of at least 50 kPa. In some embodiments, the seal  118  has a burst strength of at least 100 kPa. In some embodiments, the seal  118  has a burst strength of at least 250 kPa. In some embodiments, the seal  118  has a burst strength of at least 500 kPa. In some embodiments, the seal  118  has a burst strength of at least 750 kPa. In some embodiments, the seal  118  has a burst strength of at least 1000 kPa. 
     In some embodiments, the seal  118  has a burst strength no greater than 1250 kPa. In some embodiments, the seal  118  has a burst strength no greater than 1000 kPa. In some embodiments, the seal  118  has a burst strength no greater than 750 kPa. In some embodiments, the seal  118  has a burst strength no greater than 500 kPa. In some embodiments, the seal  118  has a burst strength no greater than 250 kPa. In some embodiments, the seal  118  has a burst strength no greater than 100 kPa. 
     It will be understood that the upper and lower limits may be combined in any variation as above to define a range for the burst strength. For example, and without limitation, the burst strength of the seal  118  may range from 50 kPa to 250 kPa. In another non-limiting example, the burst strength of the seal  118  may range from 500 kPa to 1000 kPa. Other ranges are possible. 
     In many embodiments, the battery housing  100  serves to hermetically enclose or seal the electrode assembly  102 . In these embodiments, the receptacle  104 , the lid  106 , and the seal  118  are operable to prevent elements in an ambient environment of the battery housing  100  (e.g., dust, liquids, etc.) from entering the battery housing  100 . Other components may also be involved (e.g., the feedthrough  114 ). The battery housing  100  also serves as a barrier to gaseous species that might otherwise diffuse through its structure. Non-limiting examples of such gaseous species include water vapor (or moisture) and oxygen. It will be appreciated that, when the lid  106  displaces in response to swelling of the electrode assembly  102 , the battery housing  100  retains its ability to exclude elements from the ambient environment. The battery housing  100  also retains its barrier functionality to gaseous species. 
     In some embodiments, the battery housing  100  is configured to provide a helium leak rate no greater than 1×10 −3  standard cm 3 /s. In some embodiments, the battery housing  100  is configured to provide a helium leak rate no greater than 1×10 −4  standard cm 3 /s. In some embodiments, the battery housing  100  is configured to provide a helium leak rate no greater than 1×10 −5  standard cm 3 /s. In some embodiments, the battery housing  100  is configured to provide a helium leak rate no greater than 1×10 −6  standard cm 3 /s. In some embodiments, the battery housing  100  is configured to provide a helium leak rate no greater than 1×10 −7  standard cm 3 /s. 
     In embodiments where the lid  106  includes the laminate, the laminate may have permeability represented by a helium leak rate. In some embodiments, the permeability of the laminate is no greater than 1×10 −5  standard cm 3 /s of helium. In some embodiments, the permeability of the laminate is no greater than 1×10 −6  standard cm 3 /s of helium. In some embodiments, the permeability of the laminate is no greater than 1×10 −7  standard cm 3 /s of helium. In some embodiments, the permeability of the laminate is no greater than 1×10 −8  standard cm 3 /s of helium. In some embodiments, the permeability of the laminate is no greater than 1×10 −9  standard cm 3 /s of helium. 
     In embodiments where the seal  118  includes a hermetic seal, the hermetic seal may also have a permeability represented by a helium leak rate. In some embodiments, the permeability of the hermetic seal is no greater than 1×10 −3  standard cm 3 /s of helium. In some embodiments, the permeability of the hermetic seal is no greater than 1×10 −4  standard cm 3 /s of helium. In some embodiments, the permeability of the hermetic seal is no greater than 1×10 −5  standard cm 3 /s of helium. In some embodiments, the permeability of the hermetic seal is no greater than 1×10 −6  standard cm 3 /s of helium. In some embodiments, the permeability of the hermetic seal is no greater than 1×10 −7  standard cm 3 /s of helium. 
     In  FIGS. 1A-1B , the battery housing  100  is depicted as being rectangularly-shaped. However, this depiction is not intended as limiting. The battery housing  100  may have any shape that allows an electrode assembly to be disposed within an open space of a receptacle and be sealed therein by a lid. For example, and without limitation, the battery housing  100  may be cylindrically-shaped. In another non-limiting example, the battery housing  100  may have a top surface with a slope. In yet another non-limiting example, the battery housing  100  may include an inner side wall and an outer side wall. The inner and outer side walls may define a hole through the battery housing  100 . In still yet another non-limiting example, one or both of the receptacle  104  or the lid  106  may have an indent disposed therein. Other configurations are possible.  FIGS. 1A &amp; 1B  also depict the electrode assembly  102  as a stack of layers in a planar configuration. However, this depiction is for purposes of illustration only. The electrode assembly  102  may have other configurations, such as a wound configuration (e.g., a “jelly roll”). 
     Although the receptacle  104  and the lid  106  are shown in  FIGS. 1A &amp; 1B  as having mating flanges to form the seal  118 , other configurations of the receptacle  104  and the lid  106  are possible to form the seal  118 .  FIG. 1C  presents a cross-sectional view of the battery housing  100  of  FIG. 1B , but in which the receptacle  104  and the lid  106  form the seal  118  on an edge  126  of the side wall  108 , according to an illustrative embodiment. Mating flanges are absent the receptacle  104  and the lid  106 , and the electrode assembly  102  is contained entirely within the open space  110 . Moreover, the lid  106  lacks a pocket (e.g., the pocket  120 ) and runs flat across the open space  110 . 
     It will be understood that the edge  126  need not terminate in a flat surface, such as shown in  FIG. 1C . For example, and without limitation, the edge  126  may have a protrusion extending therefrom that is narrower in thickness than the side wall  108 . The protrusion may serve to increase a surface area of the edge  126 , thereby increasing a surface area available for sealing. Non-limiting examples of cross-sections for the protrusion include hemispherical cross-sections and rectangular cross-sections. However, other types of cross-sections are possible. 
     The seal  118  may also involve exterior surfaces of the side wall  108 .  FIG. 1D  presents a cross-sectional view of the battery housing  100  of  FIG. 1B , but in which the receptacle  104  and the lid  106  form the seal  118  on an exterior surface  128  of the side wall  108 , according to an illustrative embodiment. In these embodiments, the lid  106  is configured with a portion  130  that extends past the side wall  108  (e.g., a flap) and folds over the edge  126  to be disposed adjacent the exterior surface  128 . Although not shown in  FIG. 1D , the seal  118  may optionally include the edge  126 . 
     The seal  118  may additionally involve interior surfaces of the side wall  108 .  FIG. 1E  presents a cross-sectional view of the battery housing  100  of  FIG. 1B , but in which the receptacle  104  and the lid  106  form the seal  118  on an interior surface  132  of the side wall  108 , according to an illustrative embodiment. In these embodiments, the electrode assembly  102  is below a distal surface of the side wall  108  (i.e., below the edge  126 ) and portions of the lid  106  extend into the open space  110 . The lid  106  is configured with a portion  134  that is folded to be adjacent the interior surface  132  of the side wall  108 . 
     It will be understood that, in general, the receptacle  104  and the lid  106  may be configured to form the seal  118  using any combination of edges, exterior surfaces, and interior surfaces of the side wall. Moreover, the receptacle  104  and the lid  106  are not limited to the representative configurations depicted by  FIGS. 1A-1E . Other configurations are possible. For example, and without limitation, the lid  106  may include features to control a distribution of mechanical stress in the lid  106  during displacement. Such control may also reduce tensile and shear forces experienced by the seal  118  as well as prevent mechanical stress from concentrating within lid  106  to exceed a tensile strength threshold, a burst strength threshold, or a similar kind of threshold. Non-limiting examples of features for the lid  106  include corners with radiuses as well as cross-sectional profiles that involve arcs, ogee curves, chamfers, folds, creases, ripples, bellows, and undulations. These features may be disposed in any number and position on the lid  106  capable of controlling the distribution of mechanical stress during displacement. 
     For example, and without limitation, a cross-section of the lid  106  proximate the seal  118  may include an arc, a corner having a radius, or both.  FIG. 1F  presents a cross-sectional view of the battery housing  100  of  FIG. 1B , but in which the lid  106  includes corners  136 ,  138  having radiuses, according to an illustrative embodiment. The radiuses may be increased in magnitude such that their respective corners yield an arc in cross-section. In  FIG. 1F , each of an interior-facing corner  136  and an exterior-facing corner  138  is depicted in cross-section as having a radius. However, this depiction is not intended as limiting. In some instances, only one of the interior-facing corner  136  and the exterior-facing corner  138  has a radius. 
     In another non-limiting example, a cross-section of the lid  106  may include an undulation.  FIG. 1G  presents a cross-sectional view of the battery housing  100  of  FIG. 1B , but in which the lid  106  includes an undulation  140 , according to an illustrative embodiment. The undulation  106  is operable to fold additional portions of the lid  106  along a planar orientation thereof. This compact configuration unfolds during swelling of the battery assembly  102  and may allow the lid  106  to displace without transmitting significant mechanical stresses to the seal  118 . In  FIG. 1G , the undulation  140  is depicted as having a first portion protruding away from the open space  110  and a second portion protruding into the open space  110 . However, this depicts is not intended as limiting. In some instances, the undulation  140  may include only a portion that protrudes away from the open space  110 . In other instances, the undulation  140  may include a portion that protrudes into from the open space  110 .  FIG. 1G  also depicts the undulation  140  as having a single repeat unit (i.e., a single instance of the first and second portions). However, this depiction is for purposes of illustration only. The undulation  140  may have any number of repeat units, and these repeat units may extend along any length or area of the lid  106 . 
     It will be appreciated that features to control a distribution of mechanical stress may also allow the lid  106  to include rigid portions. In such variations, the features are operable to flex or bend during swelling of the electrode assembly  102  whereas the rigid portions remain substantially unstrained, i.e., have a strain less than or equal to 0.1% (i.e., ε≤0.1%).  FIG. 1H  presents a cross-sectional view of the battery housing  100  of  FIG. 1B , but in which the lid  106  includes rigid portions  142 ,  144  and a flexible element  146  proximate the seal  118 , according to an illustrative embodiment. The flexible element  146  is configured to be mechanically weaker than the rigid portions  142 ,  144 , thus allowing the lid  106  to displace in response to a pressure or a force from the electrode assembly  102 . In  FIG. 1H , the flexible element  146  is depicted in cross-section as an ogee curve. However, this depiction is not intended as limiting. Other types of flexible elements are possible such as creases, arcs, ripples, folds, bellows, undulations, and so forth. The flexible element  146  may also be formed via a scribe or indent in rigid portions of the lid  106 . 
     The rigid portions  142 ,  144  may use materials and thicknesses described previously in relation to the receptacle  104 . In many instances, the flexible element  146  shares a material in common with the rigid portions  142 ,  144  but is configured to be weaker mechanically than the rigid portions  142 ,  144 . Such configuration may involve a shape or dimension (e.g., thickness). For example, and without limitation, both the receptacle  104  and the lid  106  may be formed of aluminum or an aluminum alloy. However, the flexible element  146  may be thinner than rigid portions  142 ,  144  of the lid  106 , such as shown in  FIG. 1H . In some embodiments, the flexible element  146  is no greater than 2 mm in thickness. In some embodiments, the flexible element  146  is no greater than 1.5 mm in thickness. In some embodiments, the flexible element  146  is no greater than 1.0 mm in thickness. In some embodiments, the flexible element  146  is no greater than 0.7 mm in thickness. In some embodiments, the flexible element  146  is no greater than 0.5 mm in thickness. In some embodiments, the flexible element  146  is no greater than 0.3 mm in thickness. 
     Now referring to  FIG. 2A , a perspective view is presented of a battery  200  for accommodating swelling of an electrode assembly  202 , according to an illustrative embodiment. The battery  200  includes a receptacle  204  and a lid  206  operable to collectively enclose the electrode assembly  202 . The lid  206  is sealed to the receptacle  204 .  FIG. 2B  presents a cross-sectional view of the battery  200  of  FIG. 2A , showing the electrode assembly  202 . In  FIG. 2B , three instances of the electrode assembly  202  are depicted as enclosed by the receptacle  204  and the lid  206 . However, this depiction is not intended as limiting. The receptacle  204  and the lid  206  may collectively enclose any number and arrangement of electrode assemblies  202 . In some embodiments, the battery  200  corresponds to a battery pack. 
     The receptacle  204  includes a side wall  208  encircling an open space  210  for containing the electrode assembly  202 . A feedthrough  214  is disposed through the side wall  208 . Although  FIG. 2A  depicts the receptacle  204  as having only one feedthrough  214 , this depiction is not intended as limiting. The receptacle  204  may include at least one feedthrough disposed through one or more sides (or walls) of the receptacle  204 . 
     A base wall  216  may further connect portions of the side wall  208  to define a bottom surface for the battery  200 . The lid  206  covers the open space  210  and couples to the receptacle  204  through a seal  218 . The receptacle  204 , the feedthrough  214 , and the lid  206  form a sealed volume in which the electrode assembly  202  and an electrolyte are disposed. In many embodiments, the lid  206  includes a laminate comprising a metal layer and a polymer layer. The metal layer may be bonded to the polymer layer. The seal  218 , which may be a hermetic seal, is formed on the side wall  208  around the open space  210 . In some embodiments, the seal  218  includes a polymer disposed on the side wall  208 . The receptacle  204  and the lid  206  are analogous to the receptacle  104  and the lid  106  described in relation to  FIGS. 1A-1H . 
     The battery  200  also includes the electrode assembly  202 . The electrode assembly  202  is disposed within the open space  210  and comprises an anode electrode (or anode) and a cathode electrode (or cathode). A separator may be interposed between each junction defined by an adjacent anode and cathode electrodes. The separator may be a microporous polymer membrane or non-woven fabric mat. The lid  206  is configured to accommodate a swelling of the electrode assembly  202  up to 15%. The receptacle  204  is configured to strain less than the lid  206  during the swelling of the electrode assembly  202 . 
     An insulating layer  222  may be disposed between the electrode assembly  202  and at least the receptacle  204 . It will be appreciated that the electrode assembly  202  may be a stack of layers, such as layers of separator that are interposed between alternating layers of anode electrode and cathode electrode.  FIG. 2B  depicts the electrode assembly  202  as having a planar configuration. However, this depiction is not intended as limiting. Other configurations are possible such as a wound configuration or “jelly roll”. In some embodiments, such as shown in  FIGS. 1A &amp; 1B , the electrode assembly  202  corresponds to a plurality of electrode assemblies  202 . In these embodiments, individual members of the plurality of electrode assemblies  202  may be electrically-coupled to each other in series, in parallel, or any combination thereof. 
     The feedthrough  214  is coupled to the anode electrode or the cathode electrode. A remaining electrode may be coupled to a second feedthrough, or alternatively, to the receptacle  204 . For the latter, the receptacle  204  is formed of electrically-conductive material. For example, and without limitation, the anode electrode may be coupled to the feedthrough  214  and the cathode electrode may be coupled to the second feedthrough (or vice versa). In another non-limiting example, the anode electrode may be coupled to the feedthrough  214  and cathode electrode may be coupled to the receptacle  204  (or vice versa). The receptacle  204  may be formed of metal, such as aluminum or an aluminum alloy. In embodiments having the plurality of electrode assemblies  202 , the feedthrough  214  may be a common feedthrough. The common feedthrough is configured to couple to each of the anode electrodes or the cathode electrodes. The second feedthrough, or alternatively, the side wall  208  may similarly be shared in common. 
     The battery  200  may be any type of battery capable of storing or supplying electrical power via an electrode assembly. Non-limiting examples of such batteries include alkaline batteries, zinc-carbon batteries, silver-zinc batteries, nickel-cadmium batteries, nickel metal hydride batteries, lithium-ion batteries, and lithium polymer batteries. However, in many embodiments, the battery  200  corresponds to a lithium-ion battery. In these embodiments, the anode active material of the anode electrode may include graphite, carbon black, silicon, or some combination thereof. The cathode active material may include a lithium metal oxide. Non-limiting examples of the lithium metal oxide include compositions represented by Li α MO δ  and Li 2 MeO 3 .Li α MO δ . Here, Me is any combination of quadrivalent metals, M is any combination of univalent, divalent, trivalent, or quadrivalent metals, 0.90≤α≤2, and 1.90≤δ≤3. Representative examples of Me include Ti, Mn, Zr, Mo, and Ru. Representative examples of M include B, Na, Mg, Ti, Ca, V, Cr, Mn, Fe, Co, Ni, Cu, Zn, Al, Sc, Y, Ga, and Zr. In some instances, the lithium metal oxide includes at least one of Co, Mn, and Ni. The anode current collector may include copper or copper foil, and the cathode current collector may include aluminum or aluminum foil. 
     The battery  200  may also include an electrolyte capable of transporting lithium ions through the separator and between the anode electrode and the cathode electrode. The electrolyte may be a liquid solvent or a gel polymer. Representative examples of the liquid solvent include an organic carbonate (e.g., ethylene carbonate, dimethyl carbonate, diethyl carbonate, ethyl-methyl carbonate, etc.), an ionic liquid (e.g., 1-butyl-3-methylimidazolium hexafluorophosphate, 1-ethylpyridinium tetrafluoroborate, etc.), or some combination thereof. Representative examples of the gel polymer include polymeric hosts such as polyethylene oxide (PEO), polyacrylonitrile (PAN), polymethylmethacrylate (PMMA), and polyvinylidene fluoride (PVdF). In many instances, the electrolyte includes a lithium salt. Non-limiting examples of the lithium salt include LiPF 6 , LiBF 4 , LiClO 4 , LiSO 3 CF 3 , LiN(SO 2 CF 3 ) 2 , LiBC 4 O 8 , Li[PF 3 (C 2 CF 5 ) 3 ], and LiC(SO 2 CF 3 ) 3 . Other lithium salts are possible, including combinations of lithium salts. It will be appreciated that the electrolyte permeates the anode active material of the anode electrode, the cathode active material of the cathode electrode, and the separator. 
     In some embodiments, the electrode assembly  202  and the lid  206  are separated by a gap. The gap may correspond to a “head space” within the battery  200  and may allow the electrode assembly  202  to swell partially or fully before contacting the lid  206 . In embodiments having the plurality of electrode assemblies  202 , the gap may be referenced against an electrode assembly closest the lid  206 . In some embodiments, such as shown in  FIG. 2B , the electrode assembly  202  and the lid  206  have no gap therebetween. 
     In some embodiments, the gap is no greater than 15% of an initial thickness of the electrode assembly  202 . In some embodiments, the gap is no greater than 12% of an initial thickness of the electrode assembly  202 . In some embodiments, the gap is no greater than 9% of an initial thickness of the electrode assembly  202 . In some embodiments, the gap is no greater than 6% of an initial thickness of the electrode assembly  202 . In some embodiments, the gap is no greater than 3% of an initial thickness of the electrode assembly  202 . In some embodiments, the gap is no greater than 1% of an initial thickness of the electrode assembly  202 . 
     In some embodiments, the gap is at least 0.5% of an initial thickness of the electrode assembly  202 . In some embodiments, the gap is at least 1% of an initial thickness of the electrode assembly  202 . In some embodiments, the gap is at least 3% of an initial thickness of the electrode assembly  202 . In some embodiments, the gap is at least 6% of an initial thickness of the electrode assembly  202 . In some embodiments, the gap is at least 9% of an initial thickness of the electrode assembly  202 . In some embodiments, the gap is at least 12% of an initial thickness of the electrode assembly  202 . 
     It will be understood that the upper and lower limits may be combined in any variation as above to define a range for the gap. For example, and without limitation, the gap may be at least 3% of an initial thickness of the electrode assembly  202  but no greater than 6%. In another non-limiting example, the gap may be at least 9% of an initial thickness of the electrode assembly  202  but no greater than 15%. Other ranges are possible. In embodiments having the plurality of electrode assemblies  202 , the initial thickness corresponds to a cumulative (or total) thickness of the plurality of electrode assemblies  202 . 
     The seal  218  may include structural features that extend past an outer periphery of the side wall  208 . In some embodiments, the receptacle  204  and the lid  206  are coupled via mating flanges configured to form the seal  218 . In some embodiments, such as shown in  FIGS. 2A &amp; 2B , the lid  206  includes a portion  230  folded over an edge  226  of the side wall  208  and sealed to an exterior surface  228  thereof. The extension of these structural features may be characterized by a distance measured perpendicular to the exterior surface  228 . It will be appreciated that the distance may be selected to reduce a protrusion of the seal  218  into space adjacent the battery  200 . Such reduction may improve a utilization of space within a target application (e.g., within an electronic device, a battery bank, etc.). 
     In some embodiments, the distance is no greater than 12 mm. In some embodiments, the distance is no greater than 10 mm. In some embodiments, the distance is no greater than 8 mm. In some embodiments, the distance is no greater than 6 mm. In some embodiments, the distance is no greater than 4 mm. In some embodiments, the distance is no greater than 3 mm. In some embodiments, the distance is no greater than 2 mm. In some embodiments, the distance is no greater than 1 mm. 
     In some embodiments, the distance is no less than 0.5 mm. In some embodiments, the distance is no less than 1 mm. In some embodiments, the distance is no less than 2 mm. In some embodiments, the distance is no less than 3 mm. In some embodiments, the distance is no less than 4 mm. In some embodiments, the distance is no less than 6 mm. In some embodiments, the distance is no less than 8 mm. In some embodiments, the distance is no less than 10 mm. 
     It will be understood that the upper and lower limits may be combined in any variation as above to define a range for the distance. For example, and without limitation, the distance may range from no less than 8 mm to no greater than 12 mm. In another non-limiting example, the distance may range from no less than 0.5 mm to no greater than 5 mm. Other ranges are possible. In some embodiments, the lid  206 , when coupled to the receptacle  204 , does not extend past an outer periphery of the side wall  208  (i.e., the distance is zero). 
     In some embodiments, the battery  200  includes a gas release valve disposed through the side wall  208 . The gas release valve is operable to vent gas (or fluid) from within the battery  200 , and some variations, may prevent the seal  218  from experiencing pressures that would exceed its burst strength. 
     The foregoing description, for purposes of explanation, used specific nomenclature to provide a thorough understanding of the described embodiments. However, it will be apparent to one skilled in the art that the specific details are not required in order to practice the described embodiments. Thus, the foregoing descriptions of the specific embodiments described herein are presented for purposes of illustration and description. They are not targeted to be exhaustive or to limit the embodiments to the precise forms disclosed. It will be apparent to one of ordinary skill in the art that many modifications and variations are possible in view of the above teachings.

Metadata:
Filing Date: 20180830
Publication Date: 20200519
Grant Date: 20200519
Priority Date: 20170925
Inventors: ZENG, Qingcheng
DAFOE, DONALD G.
Nagai, Kenzo
Assignee: APPLE INC
CPC Classifications: [{"code": "H01M2200/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01M2/08", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01M2200/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01M2/04", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01M50/186", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01M50/159", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01M50/164", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01M50/16", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01M50/193", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01M50/164", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01M50/16", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01M50/159", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01M50/193", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01M50/186", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01M50/152", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01M50/107", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01M50/15", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01M50/103", "inventive": true, "first": true, "tree": "[]"}, {"code": "Y02E60/10", "inventive": false, "first": false, "tree": "[]"}]
Family ID: 70736363