# US 11,909,058 B2 · Method and system for formation of cylindrical and prismatic can cells

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- Number: US 11,909,058 B2
- Document ID: US11909058B2
- Status: Granted
- Kind: B2
- Application number: 18/158,494
- Filed: 2023-01-24
- Published: 2023-05-25
- Granted: 2024-02-20
- Earliest claimed: 2021-07-15
- Assignees: Enevate Corporation
- Applicants: Enevate Corporation
- Inventors: Sanjaya D. Perera; Benjamin Park
- Web page: https://patentgrep.com/patent/US11909058B2

## CPC

- H01M 10/058: Construction or manufacture
- H01M 50/224: Metals
- H01M 4/134: Electrodes based on metals, Si or alloys
- H01M 10/0422: {Cells or battery with cylindrical casing}
- H01M 10/0565: Polymeric materials, e.g. gel-type or solid-type
- H01M 50/103: prismatic or rectangular (H01M50/109, H01M50/11 take precedence)
- H01M 50/107: having curved cross-section, e.g. round or elliptic (H01M50/103, H01M50/109, H01M50/11 take precedence)
- H01M 50/209: adapted for prismatic or rectangular cells (H01M50/216 takes precedence)
- H01M 50/213: adapted for cells having curved cross-section, e.g. round or elliptic (H01M50/209, H01M50/216 take precedence)
- H01M 50/231: having a layered structure
- H01M 50/494: Tensile strength
- Y02E 60/10: Energy storage using batteries
- Y02P 70/50: Manufacturing or production processes characterised by the final manufactured product
- H01M: PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- Y02E: REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS

## Abstract

A method for formation of cylindrical and prismatic can cells may include providing a battery, where the battery includes one or more cells, with each cell including at least one silicon-dominant anode, a cathode, and a separator. The battery also includes a metal can that contains the one or more cells such that during formation a pressure between 50 kPa and 1 MPa is applied to the one or more cells. The battery may include strain absorbing materials arranged between the one or more cells and interior walls of the can. The strain absorbing materials may include foam. The strain absorbing materials may include a solid electrolyte layer. The strain absorbing materials may include PMMA, PVDF, or a combination thereof. The pressure during a formation process may be due to a thickness of the strain absorbing materials being thicker than an expansion of the one or more cells.

## Claims

### Claim 1

A method of forming a battery, the method comprising:
providing a battery comprising:
one or more cells, each cell comprising at least one silicon-dominant anode, a cathode, and a separator; and
a structurally rigid metal can that contains the one or more cells such that during formation a pressure between 50 kPa and 1 MPa is applied to the one or more cells based on compression of strain absorbing materials between the structurally rigid metal can and the one or more cells, or the strain absorbing materials between the one or more cells, caused by displacement of the strain absorbing materials from expansion of the one or more cells.

### Claim 2 (depends on 1)

The method of claim 1, comprising incorporating the strain absorbing materials between the one or more cells and interior walls of the cell.

### Claim 3 (depends on 2)

The method of claim 2, wherein the strain absorbing materials comprise foam or springy material that distributes the pressure uniformly along the surface.

### Claim 4 (depends on 2)

The method of claim 2, wherein the strain absorbing materials comprise a solid electrolyte layer or semi-solid electrolyte.

### Claim 5 (depends on 2)

The method of claim 2, wherein the strain absorbing materials comprise PMMA, PVDF, or a combination thereof.

### Claim 6 (depends on 2)

The method of claim 2, wherein the strain absorbing materials comprise powder or a powder suspension of inert material such as silica, alumina, or zirconia.

### Claim 7 (depends on 2)

The method of claim 2, comprising applying the pressure to the one or more cells during a formation process due to a thickness of the strain absorbing materials being thicker than an expansion of the one or more cells during lithiation of the at least one silicon-dominant anode.

### Claim 8 (depends on 1)

The method of claim 1, wherein the battery comprises two or more cells and a first absorbing material is between one of the two or more cells and an interior wall of the structurally rigid metal can and a second absorbing material is between two of the two or more cells.

### Claim 9 (depends on 8)

The method of claim 8, wherein the first absorbing material is a different material than the second absorbing material.

### Claim 10 (depends on 8)

The method of claim 8, wherein the first absorbing material is a same material as the second absorbing material.

### Claim 11 (depends on 1)

The method to claim 1, comprising placing one or more strain absorbing materials outside the structurally rigid metal can during the formation process.

### Claim 12 (depends on 1)

The method of claim 1, wherein the formation process comprises one or more charge and discharge cycles with currents greater than 1 C.

### Claim 13

A method of forming a battery, the method comprising:
providing a battery comprising:
one or more cells, each cell comprising at least one silicon-dominant anode, a cathode, and a separator;
a structurally rigid metal can that contains the one or more cells; and
strain absorbing materials between the one or more cells and the structurally rigid metal can or between the one or more cells, such that during cycling a pressure between 50 kPa and 1 MPa is applied to the one or more cells.

### Claim 14 (depends on 13)

The method of claim 13, wherein the pressure is based on compression of the strain absorbing materials between the structurally rigid metal can and the one or more cells, or between the strain absorbing materials and the one or more cells, caused by displacement of the strain absorbing materials from expansion of the one or more cells.

### Claim 15 (depends on 13)

The method of claim 13, wherein the strain absorbing materials are incorporated between the one or more cells and interior walls of the structurally rigid metal can.

### Claim 16 (depends on 13)

The method of claim 13, wherein the strain absorbing materials comprise foam or springy material that distributes the pressure uniformly along the one or more cells.

### Claim 17 (depends on 13)

The method of claim 13, wherein the strain absorbing materials comprise powder or a powder suspension of inert material including one or more of silica, alumina, or zirconia.

### Claim 18 (depends on 13)

The method of claim 13, wherein pressure applied to the one or more cells during cycling is due to a thickness of the strain absorbing materials being thicker than an expansion of the one or more cells during lithiation of the at least one silicon-dominant anode.

### Claim 19 (depends on 18)

The method of claim 18, wherein cycling comprises one or more charge and discharge cycles with currents greater than 1 C.

### Claim 20 (depends on 13)

The method of claim 13, wherein each cell of the one or more cells comprises at least one silicon-dominant anode including at least 50% silicon by weight.