# US 12,119,458 B2 · Systems and methods for minimizing and preventing dendrite formation in electrochemical cells

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- Number: US 12,119,458 B2
- Document ID: US12119458B2
- Status: Granted
- Kind: B2
- Application number: 18/650,789
- Filed: 2024-04-30
- Published: 2024-08-29
- Granted: 2024-10-15
- Earliest claimed: 2022-12-16
- Assignees: 24M Technologies, Inc.
- Applicants: 24M Technologies, Inc.
- Inventors: Junzheng Chen; Naoki Ota; Chad Alan Hartzog; Xiaoming Liu; Michelle Robyn Brouwer; Anthony D'Angelo; Daniel Salazar; Timothy Allen Hans; Junhua Song
- Web page: https://patentgrep.com/patent/US12119458B2

## CPC

- H01M 10/0525: Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodes; Lithium-ion batteries
- H01M 10/4235: {Safety or regulating additives or arrangements in electrodes, separators or electrolyte (H01M10/4242 takes precedence)}
- H01M 4/131: Electrodes based on mixed oxides or hydroxides, or on mixtures of oxides or hydroxides, e.g. LiCoOx
- H01M 4/133: Electrodes based on carbonaceous material, e.g. graphite-intercalation compounds or CFx
- H01M 4/134: Electrodes based on metals, Si or alloys
- H01M 4/1391: of electrodes based on mixed oxides or hydroxides, or on mixtures of oxides or hydroxides, e.g. LiCoOx
- H01M 4/1393: of electrodes based on carbonaceous material, e.g. graphite-intercalation compounds or CFx
- H01M 4/1395: of electrodes based on metals, Si or alloys
- H01M 4/382: {Lithium (H01M4/405 takes precedence)}
- H01M 4/386: {Silicon or alloys based on silicon}
- H01M 4/583: Carbonaceous material, e.g. graphite-intercalation compounds or CFx
- H01M 4/587: for inserting or intercalating light metals
- H01M 10/052: Li-accumulators
- H01M 10/056: characterised by the materials used as electrolytes, e.g. mixed inorganic/organic electrolytes
- H01M 10/0562: Solid materials
- H01M 10/425: {Structural combination with electronic components, e.g. electronic circuits integrated to the outside of the casing (printed circuits H05K1/00)}
- H01M 10/4257: {Smart batteries, e.g. electronic circuits inside the housing of the cells or batteries}
- H01M 10/44: Methods for charging or discharging (circuits for charging H02J7/00)
- H01M 10/48: Accumulators combined with arrangements for measuring, testing or indicating the condition of cells, e.g. the level or density of the electrolyte (constructional details of current conducting connections for detecting conditions inside cells or batteries, e.g. details of voltage sensing terminals, H01M50/569)
- H01M 50/403: Manufacturing processes of separators, membranes or diaphragms
- H01M 50/431: Inorganic material
- H01M 50/449: having a layered structure
- H02J 7/80: including monitoring or indicating arrangements
- H01M 2004/021: {Physical characteristics, e.g. porosity, surface area}
- H01M 2004/027: {Negative electrodes}
- H01M 2004/028: {Positive electrodes}
- H01M 2010/4271: {Battery management systems including electronic circuits, e.g. control of current or voltage to keep battery in healthy state, cell balancing}
- H01M 2200/00: Safety devices for primary or secondary batteries
- H01M 2300/0068: inorganic
- Y02E 60/10: Energy storage using batteries
- H01M: PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H02J: ELECTRIC POWER NETWORKS; CIRCUIT ARRANGEMENTS OR SYSTEMS FOR SUPPLYING OR DISTRIBUTING ELECTRIC POWER; SYSTEMS FOR STORING ELECTRIC ENERGY
- Y02E: REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION

## Abstract

Embodiments described herein relate to electrochemical cells with dendrite prevention mechanisms. In some aspects, an electrochemical cell can include an anode disposed on an anode current collector, a cathode disposed on a cathode current collector, the cathode having a first thickness at a proximal end of the cathode and a second thickness at a distal end of the cathode, the second thickness greater than the first thickness, a first separator disposed on the anode, a second separator disposed on the cathode, an interlayer disposed between the first separator and the second separator, the interlayer including electroactive material and having a proximal end and a distal end, and a power source electrically connected to the proximal end of the cathode and the proximal end of the interlayer, the power source configured to maintain a voltage difference between the cathode and the interlayer below a threshold value.

## Claims

### Claim 1

A method of operating an electrochemical cell, the electrochemical cell including an anode disposed on an anode current collector, a cathode disposed on a cathode current collector, a first separator, a second separator, and an interlayer disposed between the first separator and the second separator, the method comprising:
measuring a voltage between the anode and the interlayer, the interlayer including a conductive material disposed on at least one of the first separator or the second separator; and
transferring electrical energy from the cathode to the interlayer via an external energy source, such that the voltage is maintained above a threshold voltage.

### Claim 2 (depends on 1)

The method of claim 1, wherein transferring electrical energy from the cathode to the interlayer is done by a battery management system (BMS).

### Claim 3 (depends on 1)

The method of claim 1, further comprising:
in response to the voltage decreasing below the threshold value:
closing a circuit between the anode and the cathode; and
discharging the electrochemical cell.

### Claim 4 (depends on 1)

The method of claim 1, wherein the threshold voltage is 0.1 V.

### Claim 5 (depends on 1)

The method of claim 1, wherein the voltage is a first voltage, the interlayer is a first interlayer, the electrochemical cell further includes a third separator disposed between the second separator and the cathode and a second interlayer disposed between the second separator and the third separator, the method further comprising:
measuring a second voltage between the anode and the second interlayer.

### Claim 6 (depends on 1)

The method of claim 1, wherein the interlayer includes a solid state electrolyte.

### Claim 7 (depends on 1)

The method of claim 1, wherein the interlayer includes Li(1−x) xNMC and x is between 0 and 1.

### Claim 8 (depends on 1)

The method of claim 1, wherein the interlayer includes at least one of a carbonaceous material, LFP, LCO, or NMC.

### Claim 9 (depends on 1)

The method of claim 1, wherein the cathode includes at least one of LFP, LCO, or NMC.

### Claim 10 (depends on 1)

The method of claim 1, wherein the voltage is measured by a voltage measurement device connected to an anode tab extending from the anode current collector and an interlayer tab extending from the interlayer.

### Claim 11 (depends on 10)

The method of claim 10, wherein the interlayer tab extends beyond the first separator and the second separator in a first direction and extends in a second direction opposite the first direction to a point less than about 10 mm from an edge of the first separator.

### Claim 12

An electrochemical cell, comprising:
an anode disposed on an anode current collector;
a cathode disposed on a cathode current collector;
a first separator disposed on the anode;
a second separator disposed on the cathode;
an interlayer including a conductive material disposed between the first separator and the second separator; and
a power source electrically coupled to the cathode and the interlayer, the power source configured to transfer electrical energy from the cathode to the interlayer to maintain a voltage between the anode and the interlayer above a threshold value.

### Claim 13 (depends on 12)

The electrochemical cell of claim 12, wherein the threshold value is 0.1 V.

### Claim 14 (depends on 12)

The electrochemical cell of claim 12, wherein the cathode includes at least one of LFP, LNO, or NMC.

### Claim 15 (depends on 12)

The electrochemical cell of claim 12, wherein the interlayer includes Li(1−x) xNMC and x between 0 and 1.

### Claim 16 (depends on 12)

The electrochemical cell of claim 12, wherein the anode includes at least one of graphite, lithium metal, or silicon.

### Claim 17 (depends on 12)

The electrochemical cell of claim 12, wherein the interlayer includes at least one of a carbonaceous material, LFP, LCO, or NMC.

### Claim 18 (depends on 12)

The electrochemical cell of claim 12, further comprising:
a tab extending from the interlayer, the tab extending beyond the first separator and the second separator.

### Claim 19 (depends on 18)

The electrochemical cell of claim 18, wherein the tab extends beyond the first separator and the second separator in a first direction and extends in a second direction opposite the first direction to a point less than about 10 mm from an edge of the first separator.

### Claim 20 (depends on 19)

The electrochemical cell of claim 19, further comprising:
a first film coupled to the anode current collector and contacting the tab; and
a second film coupled to the anode current collector and contacting the tab,
wherein the first film and the second film collectively form a pouch.

### Claim 21 (depends on 19)

The electrochemical cell of claim 19, further comprising:
a coupling member at least partially encircling the first separator, the second separator, and the tab.

### Claim 22 (depends on 21)

The electrochemical cell of claim 21, wherein the coupling member at least partially encircles the first film and the second film.

### Claim 23

A method of operating an electrochemical cell, the electrochemical cell including an anode disposed on an anode current collector, a cathode disposed on a cathode current collector, a first separator, a second separator, and an interlayer disposed between the first separator and the second separator, the method comprising:
transferring electrical energy from the cathode to the interlayer via a closed circuit during operation of the electrochemical cell;
measuring a voltage between the anode and the interlayer, the interlayer including a conductive material disposed on at least one of the first separator or the second separator; and
controlling the transfer of electrical energy from the cathode to the interlayer to maintain the voltage above a threshold value.

### Claim 24 (depends on 23)

The method of claim 23, wherein the threshold value is 0.1 V.

### Claim 25 (depends on 23)

The method of claim 23, wherein transferring the electrical energy from the cathode to the interlayer is done by a battery management system (BMS).

### Claim 26 (depends on 23)

The method of claim 23, further comprising:
in response to the voltage decreasing below the threshold value:
closing a circuit between the anode and the cathode; and
discharging the electrochemical cell.

### Claim 27 (depends on 23)

The method of claim 23, wherein the voltage is a first voltage, the interlayer is a first interlayer, the electrochemical cell further includes a third separator disposed between the second separator and the cathode and a second interlayer disposed between the second separator and the third separator, the method further comprising:
measuring a second voltage between the anode and the second interlayer.

### Claim 28 (depends on 23)

The method of claim 23, wherein the interlayer includes a solid state electrolyte.

### Claim 29 (depends on 23)

The method of claim 23, wherein the interlayer includes Li(1−x) xNMC and x is between 0 and 1.

### Claim 30 (depends on 23)

The method of claim 23, wherein the interlayer includes at least one of a carbonaceous material, LFP, LCO, or NMC.