HIGH CAPACITY LITHIUM ION BATTERY BUTTON CELLS

CROSS-REFERENCE

[0001] This application claims the benefit of U.S. Provisional Application Nos. 61/908,324, filed on November 25, 2013 and entitled "High Capacity Lithium Ion Battery Button Cells," and 61/908,411, filed on November 25, 2013 and entitled "Button Cell Casings Suitable for Non- Aqueous Cells," both of which are incorporated herein by reference in their entireties.

BACKGROUND OF THE INVENTION

[0002] Batteries comprise one or more electrochemical cell, such cells generally comprising a cathode, an anode and an electrolyte. Lithium ion batteries are high energy density batteries that are fairly commonly used in consumer electronics and electric vehicles. In lithium ion batteries, lithium ions generally move from the negative electrode to the positive electrode during discharge and vice versa when charging. In the as-fabricated and discharged state, lithium ion batteries often comprise a lithium compound (such as a lithium metal oxide) at the cathode (positive electrode) and another material, generally carbon, at the anode (negative electrode).

SUMMARY OF THE INVENTION

[0003] Provided herein is a multi-layered battery component, batteries comprising such components, and processes for manufacturing such components and batteries comprising such components. Generally, the multilayered battery component comprises at least one separator layer and at least one electrode layer. More specifically, the component comprises at least one separator layer, at least one anode (or negative electrode) layer, and at least one cathode (or positive electrode) layer. In more specific embodiments, the component comprises at least two separator layers, at least one anode (or negative electrode) layer, and at least one cathode (or positive electrode) layer. In some instances, such layered components are prepared in an unrolled, flat configuration, prior to be rolled into a rolled configuration (e.g., for use in a battery cell). In other instances, preparation of the multi-layered battery component in an unrolled, flat configuration is not necessary to provide a multi-layered battery component in a rolled configuration (e.g., roll-to-roll techniques are optionally utilized).

[0004] In some embodiments, a multi-layered battery component provided herein comprises a layered structure comprising at least three layers, the first layer being a separator layer, the second layer being an anode (or negative electrode) layer, and the third layer being a cathode (or positive electrode) layer. In certain embodiments, the separator layer is positioned between the anode (or negative electrode) layer and the cathode (or positive electrode) layer so as to reduce the incidence of short circuit. In further embodiments, the multi-layered battery component further comprises at least one additional separator layer, positioned on the externally facing surface (i.e., the surface not positioned in proximity to the separator layer positioned between the electrode layers) of the anode (or negative electrode) layer and the cathode (or positive electrode) layer. In some embodiments, the multi-layered battery component comprises at least five layers, the first layer being a separator layer, the second layer being an anode (or negative electrode) layer, the third layer being a cathode (or positive electrode) layer, the fourth layer being a separator layer, and the fifth layer being a separator layer. In some instances, the use a an additional (e.g., a second and optional third) separator layer on the external surface of one or more of the electrodes (e.g., the anode and/or cathode / positive and/or negative electrode) allows for rolling of multi-layered battery component, without brining the anode and cathode (or negative and positive electrodes) into contact with one another.

[0005] In some embodiments, the multi-layered battery component is a multi-layered lithium ion battery component. In some instances, the separator layer(s) comprise lithium ion battery separator layer(s), the second anode (or negative electrode) layer comprises a lithium ion battery anode (or negative electrode) layer - e.g., comprising carbon or carbon and silicon composite material(s), and the cathode (or positive electrode) layer comprises lithium ion battery cathode (or positive electrode) layer - e.g., comprising lithium metal oxide, lithium metal phosphate, or other suitable material.

[0006] In certain embodiments, anode (or negative electrode), cathode (or positive electrode), and/or separator layers comprise nanofiber material. In some instances, the use of such nanofiber materials provides flexibility to the multi-layered battery component, which facilitates rolling (e.g., tight rolling) of the multi-layered battery component. Further, in some instances, the use of nanofiber materials allows for the formation of thin layers, which may also facilitate the rolling (e.g., tight rolling) of the multi-layered battery component.

[0007] Provided in certain embodiments herein is a multi-layered battery component comprising a layered structure, the layered structure comprising:

a. a first layer (e.g., as illustrated by 103, 602), the first layer comprising a first layer first dimension li (e.g., as illustrated by 115, 623) and a first layer second dimension wi (e.g., as illustrated by 114), wherein li > wi, the first layer comprising a first first-layer- surface (e.g., as illustrated by 603) and a second first-layer-surface (e.g., as illustrated by 604), and the first layer comprising a battery separator; b. a second layer (e.g., as illustrated by 102, 605), the second layer comprising a second layer first dimension 1 ₂ (e.g., as illustrated by 624) and a second layer second dimension w ₂ , wherein 1 ₂ > w ₂ , the second layer comprising a first second-layer- surface (e.g., as illustrated by 606) and a second second-layer-surface (e.g., as illustrated by 607), the first second-layer-surface being in proximal relation to the first first-layer-surface, and the second layer comprising a positive electrode;

c. a third layer (e.g., as illustrated by 104, 608), the third layer having a third layer first dimension 1 ₃ (e.g., as illustrated by 624) and a third layer second dimension w ₃ , wherein 1 ₃ > w ₃ , the third layer comprising a first third-layer-surface (e.g., as illustrated by 609) and a second third-layer-surface (e.g., as illustrated by 610), the first third-layer-surface being in proximal relation to the second first-layer-surface, and the third layer comprising a negative electrode; and

d. a fourth layer (e.g., as illustrated by 105 / 101, 611 / 614), the fourth layer having a third layer first dimension 1 ₄ (e.g., as illustrated by 623) and a third layer second dimension w ₄ , wherein 1 ₄ > w ₄ , the fourth layer comprising a first fourth-layer- surface (e.g., as illustrated by 612 / 615) and a second fourth-layer-surface (e.g., as illustrated by 613 / 616), the first fourth-layer- surface being in proximal relation to the second second-layer-surface or the second third-layer-surface, and the fourth layer comprising a battery separator.

[0008] Generally, the second layer and the third layer are not in contact (e.g., because such contact would cause a short circuit).

[0009] In specific embodiments, li > wi. For example, the first layer optionally has a rectangular shape. In other embodiments, the first layer optionally has an oval shape. In some embodiments, 11 > 1 ₂ . In further or alternative emboidments, li > 1 ₃ . In some embodiments, wi > w ₂ . In further or alternative emboidments, wi > w ₃ . In specific embodiments, li > 1 ₂ , li > 1 ₃ , wi > w ₂ , and wi > w ₃ . In certain instances, one or more of the confirmations allow a first and second separator layer to form an envelope around the second and/or third (electrode) layer(s), reducing the incidence of short circuit. In some embodiments, W2 ~ W3. In some embodiments, 1 ₂ ¾ 1.

[0010] In some embodiments, each of Wl , W2- W3, and w ₄ are < 20 mm. In more specific embodiments, each of Wl , W2- W3, and w ₄ are < 10 mm. In more specific embodiments, each of wi , w ₂ . w ₃ , and w ₄ are < 7.5 mm. In some embodiments, each of li , 1 ₂ .1 ₃ , and 1 ₄ are < 200 mm. In more specific embodiments, each of li , 1 ₂ . 1 ₃ , and 1 ₄ are < 100 mm. Moreover, in some embodiments, the multi-layered component has a first (e.g., length) dimension and a second (e.g., width) dimension. In specific embodiments, w is <20 mm. In more specific embodiments, w is <20 mm and 1 is <200 mm. In further or alternative specific embodiments, w is <10 mm (e.g., <7.5 mm or <6 mm) and/or 1 is <100 mm.

[0011] In some embodiments, the layered battery component has a third (e.g., height) dimension h. In certain embodiments, h is < 1 mm, e.g., < 0.5 mm, or < 0.3 mm. Further, the first layer has a third dimension hi , the second layer has a third dimension h ₂ , the third layer has a third dimension h ₃ , and the fourth layer has a third dimension h ₄ . In some embodiments, each of hi , h ₂ . h ₃ , and h ₄ are < 0.3 mm. In more specific embodiments, each of hi , h ₂ . h ₃ , and h ₄ are < 0.1 mm. In certain embodiments, the cathode (or positive electrode) layer has a height (thickness) dimension (e.g., hi) of 10-150 micron. In specific embodiments, the cathode (or positive electrode) layer has a height (thickness) dimension (e.g., h ₂ ) of 50-100 micron. In some embodiments, the anode (or negative electrode) layer has a height (thickness) dimension (e.g., h ₃ ) of 1-100 micron. In specific embodiments, the cathode (or positive electrode) layer has a height (thickness) dimension (e.g., h ₃ ) of 1-50 micron. In some embodiments, a or each separator layer has a height (thickness) dimension (e.g., hi, h ₄ , and/or h ₅ ) of 10-150 micron. In specific embodiments, a or each separator layer has a height (thickness) dimension (e.g., hi, h ₄ , and/or h ₅ ) of 10-100 micron. In certain embodiments, one or more separator layer comprises separator sub-layers, each separator sub-layer comprising a height (thickness) dimension of 1-100 micron, e.g., 1-50, or 5-30 micron.

[0012] In some embodiments, the layered battery component comprises a tab attached to the second layer. In specific embodiments, at least two tabs are attached to the second layer. In some embodiments, the tab(s) comprises the same material as the second layer material, or is a current collector material (e.g., aluminum or copper). In further or alternative embodiments, the component comprises a (second) tab attached to the third layer. In specific embodiments, at least two tabs are attached to the third layer. In certain embodiments, the tab is the same material as the third layer, or is a current collector material (e.g., aluminum or copper). In some embodiments the tab(s) protrude from the layered structure (e.g., at some point along the edge thereof). In some embodiments, the second layer tab(s) protrude from the layered structure 160 to 210 degrees (e.g., about 180 degrees) relative to the third layer tab(s).

[0013] In some embodiments, the layered battery component provided herein is a rolled configuration. In some embodiments, the layered battery component is rolled along its longest dimension (generally, 1). In some embodiments, the rolled layer battery component has an aspect ratio (the ratio of the height - excluding tabs - to diameter) of < 1.2. In specific embodiments, the aspect ratio is < 1. In more specific embodiments, the aspect ratio is < 0.5. In certain embodiments, the rolled layered batter component has a rolled diameter of less than 25 mm and a rolled height of less than 10 mm.

[0014] In some embodiments, the cathode (or positive electrode) layer comprises a lithium ion battery cathode (or positive electrode) material, e.g., a lithium containing material, such as a lithium metal oxide or a lithium metal phosphate. In some embodiments, the cathode material is a nanostructured cathode material, such as a nanofiber (e.g., comprising a continuous matrix material of a lithium containing material, such as lithium metal oxide), nanoparticle, or nanocrystal. In certain embodiments, the nanostructured cathode material is a nanofiber material such as described or manufactured according to a process set forth in WO/2013/13723, filed as PCT/US 13/28186 on February 28, 2013, published on September 6, 2013, and entitled "Lithium Containing Nanofibers," which is incorporated herein for such materials and processes. In certain embodiments, the nanostructured character of the cathode materials facilitates cathode layers that are thin enough and flexible enough to be rolled in the tight configurations required for button cell electrode rolls described herein. In general instances, larger (e.g., microsized) cathode materials are incapable of being formed in such configurations with good results.

[0015] In certain embodiments, the cathode material comprises a lithium containing material of the following formula (I):

Li _a M _b X _c

(I)

[0016] In certain embodiments, M represents one or more metal element (e.g., M represents Fe, Ni, Co, Mn, V, Ti, Zr, Ru, Re, Pt, Bi, Pb, Cu, Al, Li, or a combination thereof) and X represents one or more non-metal (e.g., X represents C, N, O, P, S, S0 ₄ , P0 ₄ , Se, halide, F, CF, S0 ₂ , S0 ₂ C1 ₂ , I, Br, Si0 ₄ , B0 ₃ , or a combination thereof) (e.g., a non-metal anion). In some embodiments, a is 1-5 (e.g., 1-2), b is 0-2, and c is 0-10 (e.g., 1-4, or 1-3).

[0017] In some embodiments, X is selected from the group consisting of O, S0 ₄ , P0 ₄ , S1O ₄ , B0 ₃ . In more specific embodiments, X is selected from the group consisting of O, P0 ₄ , and Si0 . In certain embodiments, M is Mn, Ni, Co, Fe, V, Al, or a combination thereof.

[0018] In certain embodiments, a lithium material of formula (I) is LiMn ₂ 0 , LiNii ₃ Coi ₃ Mni ₃ 0 ₂ , LiCo0 ₂ , LiNi0 ₂ , LiFeP0 , Li ₂ FeP0 F, or the like. In some embodiments, a lithium material of formula (I) is LiNi _b iCo _b2 Mn _b3 0 ₂ , wherein bl + b2 + b3 = 1, and wherein 0 < bl, b2, b3 < 1. In some embodiments, a lithium material of formula (I) is LiNi _b iCo _b2 Al _b3 0 ₂ , wherein bl + b2 + b3 = 1, and wherein 0 < bl, b2, b3 < 1. In certain embodiments, a lithium material of formula (I) is LiMn ₂ 0 , LiMn _bl Fe _b2 0 ₄ (wherein bl + b2 = 2, e.g., bl = 1.5), LiMnP0 ₄ , LiNiP0 ₄ , LiCoP0 ₄ , Li ₃ V ₂ (P0 ₄ ) ₃ , Li ₂ FeSi0 ₄ , Li ₂ MnSi0 ₄ , LiFeB0 ₃ , or LiMnB0 ₃ .

[0019] In some embodiments, the anode (or negative electrode) layer comprises a lithium ion battery anode (or negative electrode) material, e.g., a carbon, silicon, tin, tin oxide, or a combination thereof. In some embodiments, the anode (or negative electrode) material is a nanostructured anode (or negative electrode) material, such as a nanofiber (e.g., composite nanofibers comprising (non- aggregated) silicon nanoparticles embedded in a carbon matrix). In specific embodiments, the nanostructured anode material is a carbon- silicon composite nanofiber, e.g., comprising (non- aggregated) silicon nanoparticles embedded in a matrix comprising carbon. In certain embodiments, the nanostructured anode material is a nanofiber material such as described or manufactured according to a process set forth in WO2013/130712, filed as PCT/US 13/28165 on February 28, 2013, published on September 6, 2013, and entitled "Silicon Nanocomposite Nanofibers," or PCT/US 14/25974 on March 13, 2014, and entitled "Carbon and Carbon Precursors in Nanofibers," or US 61/911,847, filed on December 4, 2014, and entitled "Nanostructured Carbon, Methods for Producing the Same, and Applications of Same," all of which are incorporated herein for such materials and processes. In certain embodiments, the nanostructured character of the anode materials facilitates anode layers that are thin enough and flexible enough to be rolled in the tight configurations required for button cell electrode rolls described herein. In general instances, larger (e.g., microsized) anode materials are incapable of being formed in such configurations with good results. In specific embodiments, nanostructured anode and cathode materials are preferred.

[0020] In some embodiments, the separator layer(s) comprise a lithium ion battery separator material. In specific instances, separator layer(s) independently comprise a porous polymer material (e.g., film or nanofiber mat). In certain embodiments, the separator layer(s) comprise porous materials independently comprising a polyolefin (e.g., polyethylene (PE) and/or polypropylene (PP)), polyvinylacetate (PVAc), polyvinylalcohol (PVA), polyacrylonitrile (PAN), or other suitable polymer. In specific embodiments, the porous material comprises a polyolefin (e.g., PE or PP) stretched film. For example, in some embodiments, a separator layer provided herein optionally comprises a Celgard Commercial Monolayer Polypropylene (PP) Separator, e.g., Celgard 2400, Celgard 2500, or Celgard PP2075, a Celgard Commercial Monolayer Polyethylene Separator, or a Celgard Commercial Trilayer PP/PE/PP Separator (e.g., 2325, 2320, C210, M825, M1473, M824, or the like). In further or alternative embodiments, the porous material comprises a nanofiber mat comprising nanofibers having a matrix of polyvinylacetate (PVAc), polyvinylalcohol (PVA), polyacrylonitrile (PAN), or other suitable polymer. In some embodiments, the porous polymer material (e.g., nanofibers mats) comprises (i) polymer and (ii) clay, ceramic, or a combination thereof (e.g., nanocomposite nanofibers comprising clay and/or ceramic nanostructures embedded in a polymer matrix). In some embodiments, such separators comprise nanofibrous mats comprising polymer nanofibers and composite nanofibers, e.g., as set forth in US 7,083,854, which is incorporated herein for such disclosure. Further, a separator layer provided herein optionally comprises multiple sub-layers comprising one or more of these types of separators.

[0021] In certain embodiments, provided herein is a battery cell (e.g., a secondary battery) comprising a multi-layered battery component provided herein. In some embodiments, the battery cell is a button cell (e.g., a cell having a diameter of less than 25 mm and a height of less than 10 mm). In certain embodiments, the battery cell is a lithium ion battery cell. In some embodiments, such cells have an energy density of at least 75 mAh/L. In more specific embodiments, the cells have an energy density of at least 90 mAh/L. In more preferred embodiments (e.g., wherein nanostructured cathode and anode materials are utilized), the cells have an energy density of at least 300 mAh/L. In still more preferred embodiments, such cells have an energy density of at least 350 mAh/L.

[0022] In specific instances, the cell is a size 312 (e.g., a cell having a diameter of about 7.9 mm and a height of about 3.6 mm) secondary lithium ion battery cell and has an energy density of at least 5 mAh. In specific instances, the cell is a size 312 (e.g., a cell having a diameter of about 7.9 mm and a height of about 3.6 mm) secondary lithium ion battery cell and has an energy density of about 6 mAh, or more. In some embodiments, such cells comprise a multi-layered battery component provided herein wherein the cathode (or positive electrode layer) comprises nanostructured lithium material (e.g., nanostructured lithium metal oxide) and the anode comprises composite nanofibers comprising (non-aggregated) silicon nanoparticles embedded in a carbon matrix. [0023] In specific embodiments, the cell is a size 13 (e.g., a cell having a diameter of about 7.9 mm and a height of about 5.4 mm) secondary lithium ion battery cell and has an energy density of at least 9 mAh. In specific instances, the cell is a size 312 (e.g., a cell having a diameter of about 7.9 mm and a height of about 5.4 mm) secondary lithium ion battery cell and has an energy density of about 10 mAh, or more. In some embodiments, such cells comprise a multi-layered battery component provided herein wherein the cathode (or positive electrode layer) comprises nanostructured lithium material (e.g., nanostructured lithium metal oxide) and the anode comprises composite nanofibers comprising (non-aggregated) silicon nanoparticles embedded in a carbon matrix.

[0024] Development of small-format batteries containing high energy densities is a critical challenge with unique challenges. There does not yet exist a suitable rechargeable secondary non-aqueous battery in the small-format button cell configuration. The current technology generally consists of primary cells, particularly zinc-air cells.

[0025] One of the main challenges facing the implementation of rechargeable technology in these cells is the aspect ratio of the diameter to the height. The relatively small surface area of the bottom coupled with the long side dimension create an unfavorable internal volume space for thin-film stacking of electrodes, leaving a large area to be filled by spacers which add unnecessary package weight to the product, e.g., as illustrated by FIG. 7.

[0026] The components provided are able to take advantage of the space available by filling the tall, narrow volume inside small-format button cells such as the 13 cell. In this form factor, the conventional stacking configuration does not allow for the maximum utilization of the space. In some instances, the components provided herein make a miniature roll which can be inserted perpendicular to the diameter of the casing in order to more efficiently utilize the limited space available.

[0027] As described in more detail herein, in some embodiments, one or more positive and negative leads (e.g., via tabs provided herein) are accessible on opposite ends of the electrode roll, and negative and positive electrodes are separated by a non-conductive polymer film with two or more separators. In some embodiments, the height of this electrode roll does not exceed 0.5 cm, with a diameter less than 0.55 cm. In some instances, this prepared electrode roll can be inserted into a suitable cell housing (e.g., a 13 button cell).

[0028] In certain embodiments, provided herein is a process of manufacturing a battery cell (e.g., lithium ion button cell) comprising providing a layered battery component described herein, rolling the layered battery component (e.g., around a dowel) into a cylindrical configuration, and inserting the rolled layered battery component into a battery housing. In certain embodiment, the process further comprises attaching the electrode tabs to the battery housing (e.g., to the top and bottom).

BRIEF DESCRIPTION OF THE DRAWINGS

[0029] The novel features of the invention are set forth with particularity in the appended claims. A better understanding of the features and advantages of the present invention will be obtained by reference to the following detailed description that sets forth illustrative embodiments, in which the principles of the invention are utilized, and the accompanying drawings of which:

[0030] FIG. 1 illustrates a schematic of a topological view (with cut-outs of some of the layers) of an exemplary multi-layered battery component provided herein.

[0031] FIG. 2 illustrates a schematic of an exemplary multi-layered battery component provided herein in a rolled configuration.

[0032] FIG. 3 illustrates a schematic of an exemplary battery cell comprising a multi-layered battery component provided herein in a battery cell housing (cross-section of the housing).

[0033] FIG. 4 illustrates a schematic of a partially assembled battery cell provided herein (cross- section of the housing).

[0034] FIG. 5 illustrates the charge and discharge capacity of an exemplary lithium ion battery button cell comprising a multi-layered battery component described herein.

[0035] FIG. 6 illustrates a schematic of a longitudinal cross-sectional view of an exemplary multi- layered battery component provided herein.

[0036] FIG. 7 illustrates an alternate configuration for manufacturing a button cell that provides much lower performance than the multi-layered, rolled configuration provided herein.

[0037] FIG. 8 illustrates a cross-sectional view of a button cell comprising a multi-layered rolled electrode configuration positioned therein.

[0038] FIG. 9 illustrates the charge and discharge capacity of an exemplary lithium ion battery button cell comprising a multi-layered battery component described herein using nanostructured electrode materials.

DETAILED DESCRIPTION OF THE INVENTION

[0039] FIG. 1 illustrates a topological perspective of one embodiment of a multi-layered battery component provided herein. (The figure illustrates cut-outs of some layers (101, 102, 103) for illustrative purposes so that the multiple layers may be viewed from a topological perspective.) In some embodiments, the multi-layered battery component 100 comprises a first layer 103, the first layer being a separator layer (i.e., comprising a separator material), a second layer 102, the second layer being an cathode (or positive electrode) layer (i.e., a layer comprising a cathode material - such a lithium metal oxide, lithium metal phosphate, or the like), and a third layer 104, the third layer an anode (or negative electrode) layer (i.e., a layer comprising an anode material - such as carbon or a carbon and silicon composite - e.g., nanofiber composite thereof). Generally, the separator is positioned between the anode (or negative electrode) layer 104, and the cathode (or positive electrode) layer 102. At least one additional separator layer is preferred, particularly if the multi- layered component is going to be utilized in a rolled configuration. The at least one additional separator layer is optionally positioned in proximal relation (e.g., adjacent or in contact with, or in operable contact with, via a liquid electrolyte) to the anode or cathode. In specific instances, the multi-layered battery component 100 optionally comprises a separator layer 101 in proximal relation to the cathode (or positive electrode) 102 and a separator layer 105 in proximal relation to the anode (or negative electrode) 104. A cross-section 118 along the plane 113 illustrates the cathode (or positive electrode) 102 positioned between two separator layers 101 and 103, and the anode (or negative electrode) 104 positioned between two separator layers 103 and 105. The figure illustrates a rectangular configuration, but other configurations, such as ovals or other shapes are optionally utilized. In some instances, the component has a length (1) dimension (e.g., the longest dimension, if present) 115 terminating in a first end 108 and second end 109 of the component. Each layer also has a length dimension, which may be same or different (shorter) than the dimension of the component. For example, the anode (or negative electrode) layer 104 of the figure is illustrated as being shorter than the overall component 100. In specific embodiments, the electrode layers of components provided herein are both (or all) shorter than the overall component. Further, each layer optionally abuts one or more end of the component, or is recessed therefrom. For example, the figure illustrates one layer 104 that is recessed from one end 109 and other layers 102 and 103 that abut an end 108 of the component. In specific embodiments of components provided therein, each electrode layer is recessed at both ends of the component. In some instances, one or more separator layer abuts and/or forms the end(s) of the component, e.g., as illustrated in FIG. 1. In some instances, the component has a width (w) dimension (e.g., orthogonal to the longest dimension, if present) 114 terminating in a first edge 111 and second edge 112 of the component. Each layer also has a width dimension, which may be same or different (shorter) than the dimension of the component. For example, the anode (or negative electrode) layer 104 and cathode (or positive electrode) 102 of the figure are illustrated as having a shorter width than the overall component 100. In specific embodiments, the electrode layers of components provided herein both (or all) have a shorter width than the overall component. Further, each layer optionally abuts one or more edge of the component, or is recessed therefrom. For example, the figure illustrates both electrode layers 102 and 104 that are recessed from both edges 111 and 112, whereas the separator layers 101, 102 and 103 all abut (and form) the edges 111 and 112 of the component. In specific embodiments of components provided therein, each electrode layer is recessed at both edges of the component. In some instances, one or more separator layer abuts and/or forms the edge(s) of the component, e.g., as illustrated in FIG. 1. In some instances, as illustrated in the cross-section 118, when the electrode components are recessed from the edges (and/or ends) of the component, the separator layers are optionally crimped (or otherwise come into contact) at the edges, or around the electrode(s), enclosing (or at least partially enclosing) the electrode layers within a separator envelope. In some instances, the multi-layered components also comprise electrode and/or current collector tabs. In some embodiments, a multilayered component provided herein comprises a conductive tab 107 in contact with cathode (or positive electrode) layer 102. In certain instances, this tab has a length sufficient to allow it to protrude beyond an edge 112 of the layers of the multi-layered component. Similarly, in some embodiments, a multilayered component provided herein comprises a conductive tab 106 in contact with the anode (or negative electrode) layer 104. In certain instances, this tab has a length sufficient to allow it to protrude beyond an edge 111 of the layers of the multi- layered component. In certain embodiments, the tabs comprise a material similar to the electrode material with which they are in contact with, or a current collector material. In some embodiments, the anode tab and the cathode tab are positioned so as to protrude from the component in opposite latitudinal directions (e.g., 120 to 210 degrees, such as about 180 degrees, to each other, such as illustrated in FIG. 1).

[0040] FIG. 6 illustrates a cross-sectional view 600, along a longitudinal plane 601, of an exemplary multi-layered battery component 100 provided herein. In some embodiments, the multi-layered battery component 100 comprises a first layer 602, the first layer comprising a first surface 603 and a second surface 604. In specific instances, the first layer is a separator layer (i.e., comprising a separator material). In certain embodiments, the first surface 603 of the first layer 602 is in proximal relation (e.g., in contact with or adjacent to) the first surface 609 of a second layer 608. In some embodiments, the second layer is a cathode (or positive electrode) layer (i.e., a layer comprising a cathode material - such a lithium metal oxide, lithium metal phosphate, or the like). In some embodiments, the second surface 604 of the first layer 602 is in proximal relation (e.g., in contact with or adjacent to) the first surface 606 of a third layer 605. In some instances, the third layer is an anode (or negative electrode) layer (i.e., a layer comprising an anode material - such as carbon or a carbon and silicon composite). In specific instances, the separator 602 is positioned between the anode (or negative electrode) layer 605, and the cathode (or positive electrode) layer 608. At least one additional separator layer is preferred, particularly if the multi-layered component is going to be utilized in a rolled configuration. The at least one additional separator layer is optionally positioned in proximal relation to (e.g., adjacent to or in contact with, or in operable contact with, via a liquid electrolyte) the anode layer 605 or cathode layer 609. In some instances, the multi-layered battery component 100 optionally comprises a separator (or insulating) layer 611, with the first surface 612 of the separator (or insulating) layer 611 in proximal relation to a second surface 610 of the cathode (or positive electrode) layer 609. In further or alternative embodiments, the multi-layered battery component 100 optionally comprises a separator (or insulating) layer 614, with the first surface 615 of the separator (or insulating) layer 614 in proximal relation to a second surface 607 of the anode (or negative electrode) layer 605. In some instances, the second and/or third layer is a separator or insulating layer so as to prevent cathode and anode contact (and, thereby, short circuit) of the multi- layered battery component when in a rolled configuration. In some embodiments, the multi-layered battery component 100 has an overall thickness 617 that is thin enough to facilitate rolling of the component into a rolled configuration (e.g., as illustrated in FIG. 2). The first layer (e.g., separator layer) 602 thickness 618, the second layer (e.g., cathode layer) 608 thickness 620 and the third layer (e.g., anode layer) 605 thickness 619 may be the same or different. In specific embodiments, the thickness of the anode layer 605 is thinner than the cathode layer 608. Optional separator (or insulator) layers 611 and 614 also have thicknesses 621 and 622 that may be the same or different. In addition, these outer separator layers are optionally thinner or thicker than the inner separator layer (positioned between the electrode layers of the multi-layered battery component). In some instances, any one or more of the separator layers is optionally comprised of a plurality of separator sub-layers (e.g., a separator is optionally folded over one or more times, creating a separator layer having a plurality of sub-layer components - for example, if the separator layer has one fold, it may have two sub-layers - configured like a V - or if it has three folds, it may have four sub-layers - configured like a W). In some instances, the component has a length (1) dimension (e.g., the longest dimension, if present) 623 terminating in a first end and second end of the component. Each layer also has a length dimension, which may be same or different (shorter) than the dimension of the component. For example, FIG. 6 illustrates the anode (or negative electrode) layer 605 and cathode (or positive electrode) 608 having a length 624 that is shorter than the length of the overall component 623. Further, such electrodes optionally have the same (as illustrated) or different lengths from each other. Similarly, the separator layer(s) optionally have the same or different length as each other (if there is more than one separator layer) and/or the same or different length as each or both of the electrode layers.

[0041] In some embodiments, the separator layers comprise a single separator sheet that is folded in such a way as to cover the inner and outer surfaces of both the anode (or negative electrode) layer and the cathode (or positive electrode) layer.

[0042] FIG. 2 illustrates one embodiment of a multi-layered battery component 200 provided in a rolled configuration. In some instances, a multi-layered battery component 200 is rolled around an axis 205 (e.g., along its longest dimension or length). As illustrated by the figure, a plurality of layers of the multi-layered component 200 can be obtained in the rolled configuration. An outer roll layer of the component has an external surface 201 and an internal surface 202. An inner roll layer of the component has an external surface 206 and an internal surface 207. In some embodiments, the external surfaces 201 and 206, the internal surfaces 202 and 207, or both comprise a separator (e.g., a separator layer of the multi-layered battery component 200) (or other insulating or non-electrode or non-conducting material). In certain instances, the configuration of the separator (or other insulating or non-electrode or non-conducting material) on the internal and/or external surface(s) of the rolled component prevent direct contact between the electrodes in the various rolled layers. Current collector (or electrode) tabs are illustrated in a first direction 203 and a second direction 205. As discussed herein, these tabs are generally pointed in generally opposing directions (e.g., 150-210 degrees, or about 180 degrees, to one another to avoid short circuit of a battery comprising the component). Once rolled, the multi-layered battery component has a height (e.g., a height excluding the tabs, if present) 208, which may generally correlate to the width of the unrolled-multi-layered component 114, and a diameter 209. [0043] FIG. 3 illustrates a battery cell (e.g., a button cell) 300 having a height 309 and a diameter 312 comprising a multi-layered battery component 302 provided herein in the rolled configuration 308 and a battery housing. The battery housing comprises a lid 305 and a base 301. In some instances, the multi-layered battery component 302 comprises a first tab 306 (e.g., which is attached to either the anode or the cathode layer of the multi-layered battery component) and a second tab 303 (e.g., which is attached to the other of the anode or the cathode layer of the multi-layered battery component), the first tab 306 being attached 307 to the lid 305 and second tab 303 being attached 304 to the base 301. Attachment can be achieved by any suitable process, and may simply include putting the tab into contact with the appropriate battery-housing component. Generally, the diameter 314 of the rolled multi-layered battery component 302 is less than the internal diameter of the battery housing (e.g., the internal diameter of both the base 313 and the lid). Similarly, the height 311 of the rolled multi- layered battery component 302 is less than the internal height of the battery housing 310. Exemplary button cells utilized herein are button cells having a diameter of about 11.6 mm and a height of about 4.2 mm (e.g., a 301-format button cell) and button cells having a diameter of about 11.6 mm and a height of about 5.4 mm (e.g., a 13-format button cell). FIG. 8 illustrates a similar battery cell 800 configuration, demonstrating a cross section of the multilayered battery component (electrode roll) 801 and comprising a seal 802 configured between the lid and base to hermetically seal the battery cell chamber 803.

[0044] In some embodiments, the height of a multi-layered battery component provided herein in the rolled configuration is small enough to fit in a button cell battery housing. For example, in some embodiments, the height of a multi-layered battery component provided herein in the rolled configuration is less than 20 mm. In more specific embodiments, the height of the multi-layered battery component in the rolled configuration is less than 15 mm. In yet more specific embodiments, the height of the multi-layered battery component in the rolled configuration is less than 10 mm. In yet more specific embodiments, the height of the multi-layered battery component in the rolled configuration is 2-10 mm. In still more specific embodiments, the height of the multi-layered battery component in the rolled configuration is less than 6 mm. In some embodiments, the diameter of a multi-layered battery component provided herein in the rolled configuration is small enough to fit in a button cell battery housing. For example, in some embodiments, the diameter of a multi-layered battery component provided herein in the rolled configuration is less than 30 mm. In more specific embodiments, the diameter of the multi-layered battery component in the rolled configuration is less than 25 mm. In some embodiments, the diameter of the multi-layered battery component in the rolled configuration is 5-30 mm. In specific embodiments, the height of the multi-layered battery component in the rolled configuration is 5-25 mm. Generally, the configuration of the button cell housings are such that the diameter of the cell is greater than the height. In some embodiments, the aspect ratio (height-to-diameter) of a multi-layered battery component provided herein is 1.2 or less. In specific embodiments, the aspect ratio (height-to-diameter) of a multi-layered battery component provided herein is 1 or less. In more specific embodiments, the aspect ratio (height-to-diameter) of a multi- layered battery component provided herein is 0.9 or less. In still more specific embodiments, the aspect ratio (height-to-diameter) of a multi-layered battery component provided herein is 0.8 or less. In yet more specific embodiments, the aspect ratio (height-to-diameter) of a multi-layered battery component provided herein is 0.6 or less. In still more specific embodiments, the aspect ratio (height- to-diameter) of a multi-layered battery component provided herein is 0.5 or less.

[0045] FIG. 4 illustrates a partially assembled battery cell 400 provided herein. The battery housing comprises a lid 401 that is in contact with (attached to) 404 a first tab 405 of a multi-layered battery component 402 provided herein. The battery housing comprises a base 403 that is in contact with (attached to) 407 a second tab 408 of a multi-layered battery component 402 provided herein. Such contact (or attachment) may be achieved concurrently with, or prior to, assembly of the lid 401 in the base 403.

[0046] In some embodiments, provided herein is a process of assembling a button cell, the process comprising:

a. providing a multilayered battery component herein (e.g., a multi-layered battery component in a rolled configuration, the multilayered battery component comprising a first tab attached to an anode layer of the multi-layered battery component, and a second tab attached to a cathode layer of the multi-layered battery component);

b. providing a button cell lid (e.g., having the battery housing parameters as described herein);

c. providing a button cell base(e.g., having the battery housing parameters as described herein);

d. contacting the first tab with either the battery cell lid or battery cell base; e. contacting the second tab with the other of the battery cell lid or the battery cell base (i.e., the one to which the first tab is not attached);

f. assembling the battery lid within the battery base, enclosing the multi-layered battery component within an assembled battery housing; and

g. optionally crimping the base (e.g., so as to hold the lid in place) (an exemplary un- crimped base is illustrated in FIG. 4 and an exemplary crimped base in FIG 3).

[0047] FIG. 5 illustrates the capacity of a size 13 battery comprising a rolled configuration described herein, wherein the separator layers comprise a stretched polyolefin film, the cathode layer comprises a lithium metal oxide powder composition formed into a film, and the anode layer comprises a carbon powder composition formed into a film. As can be seen, the results provide a lithium ion size 13 battery having a discharge capacity of about 1.6 mAh, which is substantially higher than an alternative configuration utilizing a configuration as illustrated in FIG. 7. The cell illustrated in FIG. 7, comprising within a battery housing 701 and 702 a lithium metal oxide powder film layer as the cathode 703, a stretched polyolefin film as the separator 704, a carbon powder film as the anode 705, and a spacer and/or spring 706 (e.g., to maintain configuration of the cathode, separator and anode in proximity to one another, and, optionally, functioning as a current collector for the anode (or cathode - depending on which side it is placed)). In some instances, such stacked configuration provide discharge capacities only on the order of 0.1 mAh, i.e., less than 10% of the rolled configuration described herein). Moreover, FIG. 9 illustrates the even greater (10 fold greater) capacity of a size 13 battery comprising a rolled configuration described herein, wherein nano structured electrode components (e.g., nano structured lithium metal oxide cathode materials and nanostructured silicon- carbon composite materials), with a capacity of at least 15 mAh.

EXAMPLES

Example 1

[0048] FIG. 5 illustrates the capacity of a size 13 battery comprising a rolled configuration described herein, wherein the separator layers comprise a stretched polyolefin film, the cathode layer comprises a lithium metal oxide powder composition formed into a film, and the anode layer comprises a carbon powder composition formed into a film. As can be seen, the results provide a lithium ion size 13 battery having a discharge capacity of about 1.6 mAh, which is substantially higher than an alternative configuration utilizing a configuration as illustrated in FIG. 7.

Example 2

[0049] An AG5 (size 13) button cell was prepared comprising a rolled configuration described herein, wherein the separator layers comprise a stretched polyolefin film, the cathode layer comprises a nanostructured lithium metal oxide powder composition (Li-NMC) formed into a film, and the anode layer comprises a silicon-carbon composite nanofiber composition formed into a film. As can be seen in FIG. 9, the results provide a lithium ion button cell having charge and discharge capacities of greater than 15 mAh.