Source: http://www.google.com/patents/US20070269685?dq=5191154
Timestamp: 2017-12-13 12:03:34
Document Index: 140486645

Matched Legal Cases: ['§120', '§119', 'Application No. 60', '§119', 'Application No. 60', 'Application No. 60']

Patent US20070269685 - Battery cell design and method of its construction - Google Patents
A compact, robust, multifunctional and highly manufacturable rechargeable cylindrical electrochemical cell is provided. In some embodiments, a cell can include a spirally wound assembly having an anode sheet and a cathode sheet separated by separator membranes, each sheet having a electroactive layer...http://www.google.com/patents/US20070269685?utm_source=gb-gplus-sharePatent US20070269685 - Battery cell design and method of its construction
Publication number US20070269685 A1
Application number US 11/748,286
Also published as US8084158
Publication number 11748286, 748286, US 2007/0269685 A1, US 2007/269685 A1, US 20070269685 A1, US 20070269685A1, US 2007269685 A1, US 2007269685A1, US-A1-20070269685, US-A1-2007269685, US2007/0269685A1, US2007/269685A1, US20070269685 A1, US20070269685A1, US2007269685 A1, US2007269685A1
Inventors Andrew Chu, Antoni Gozdz, Gilbert Riley, C. Hoff
Patent Citations (30), Referenced by (47), Classifications (11), Legal Events (5)
Battery cell design and method of its construction
US 20070269685 A1
A compact, robust, multifunctional and highly manufacturable rechargeable cylindrical electrochemical cell is provided. In some embodiments, a cell can include a spirally wound assembly having an anode sheet and a cathode sheet separated by separator membranes, each sheet having a electroactive layer on a current collector. At least one of the current collectors can be in electrical communication with conducting tabs that extend from at least one of the anode sheet and the cathode sheet, the conducting tabs extends from an end face of the spirally wound assembly. The centers of the plurality of conducting tabs can be located within a 90 degree quadrant of an end face of the spirally wound assembly.
wherein centers of the plurality of conducting tabs are located within a 90 degree quadrant of the end face of the spirally wound assembly.
9. The cylindrical electrochemical cell of claim 1, wherein the plurality of conducting tabs intersect at a central axis when folded towards the center of the end face.
11. The cylindrical electrochemical cell of claim 10, wherein the lengths of the tabs are selected so that the ends of the tabs are aligned when folded.
14. The cylindrical electrochemical cell of claim 13, wherein the connecting strap is electrically connected to a terminal of a case housing the spirally wound electrochemical assembly
wherein at least one of the first current collector and the second current collector is in electrical communication with a plurality of 4 to 12 conducting tabs that extend from at least one of the anode sheet and the cathode sheet at an end face of the spirally wound assembly.
19. The cylindrical electrochemical cell of claim 15, wherein the plurality of conducting tabs are located within a 90 degree quadrant of an end face of the spirally wound assembly.
20. The cylindrical electrochemical cell of claim 15, wherein the locations of the plurality of conducting tabs are selected such that net magnetic fields caused by induced currents in the cylindrical electrochemical cell is reduce by at least 80% compared to having only a single conducting tab located at a leading edge of the at least one of the anode sheet and the cathode sheet.
21. The cylindrical electrochemical cell of claim 15, wherein the plurality of conducting tabs intersect at a central axis when folded towards the center of the end face.
22. The cylindrical electrochemical cell of claim 15, wherein the plurality of conducting tabs are of different lengths.
23. The cylindrical electrochemical cell of claim 22, wherein the lengths of the tabs are selected so that the ends of the tabs are aligned when folded.
24. The cylindrical electrochemical cell of claim 15, wherein the cylindrical electrochemical cell comprises 1 tab per 50 cm2 to 400 cm2 area of anode and cathode sheet.
25. The cylindrical electrochemical cell of claim 15, wherein the plurality of conducting tabs are secured to a connecting strap.
26. The cylindrical electrochemical cell of claim 25, wherein the connecting strap is electrically connected to a terminal of a case housing the spirally wound electrochemical assembly
27. A method of making an electrochemical cell, comprising:
interposing a separator membrane between a positive electrode comprising a first electroactive layer on a first current collector and a negative electrode comprising a second electroactive layer on a second current collector to form a multilayer assembly,
wherein each of the current collectors has a plurality of conductive tabs in electrical contact with and extending outward from the current collectors, wherein the tabs of the positive electrode and the tabs of the negative electrode are on opposite sides of the multilayer assembly,
spirally winding the multilayer assembly such that the tabs of a selected current collector are aligned within a 90 degree quadrant of an end face of the spirally wound assembly,
folding the tabs of the selected current collector towards the center of the spiral wound assembly such that the tabs intersect one another at a central axis;
collecting the overlapped tabs of the selected current collector at a point beyond the tab intersection;
securing the collected tabs of the selected current collector to a connecting strap.
28. The method of claim 26, wherein tab lengths are select such that the collected tabs are aligned at their terminal edges.
29. The method of claim 26, wherein the tabs of the selected current collector are uniformly spaced along a length of the selected current collector.
30. A cylindrical electrochemical cell, comprising:
wherein at least one of the first current collector and the second current collector is in electrical communication with a plurality of conducting tabs that extend from at least one of the anode sheet and the cathode sheet, the plurality of conducting tabs extends from an end face of the spirally wound assembly; and
wherein the locations of the plurality of conducting tabs are selected such that net magnetic fields caused by induced currents in the cylindrical electrochemical cell is reduce by at least 80% compared to having only a single conducting tab located at a leading edge of the at least one of the anode sheet and the cathode sheet.
31. A method of providing pulsed power, comprising:
providing an electrochemical cell, comprising a spirally wound assembly comprising an anode sheet and a cathode sheet separated by separator membranes, the cathode sheet comprising a first electroactive layer on a first current collector, and the anode sheet comprising a second electroactive layer on a second current collector, the spirally wound assembly having a cylindrical side wall and opposing end faces,
wherein at least one of the first current collector and the second current collector is in electrical communication with a plurality of 4 to 12 conducting tabs that extend from at least one of the anode sheet and the cathode sheet at an end face of the spirally wound assembly; and
applying an intermittent load to the electrochemical cell, wherein an induced magnetic field is generated around a closed current loop in at least one of the cathode sheet and anode sheet, said induced magnetic field being substantially cancelled by an adjacent magnetic field such that the overall induced magnetic field is about zero.
This is application is a continuation-in-part of and claims priority under 35 U.S.C. §120 to U.S. patent application Ser. No. 11/515,597, filed Sep. 5, 2006, and which claims the benefit of priority under 35 U.S.C. §119(e), to U.S. Application No. 60/714,171, filed Sep. 2, 2005, both of which are entitled “Battery Cell Design and Method of Its Construction,” which are hereby incorporated by reference in their entirety.
This application also claims the benefit under 35 U.S.C. §119(e) of U.S. Provisional Patent Application No. 60/799,873, filed May 12, 2006, entitled “Low-Inductance Cylindrical Battery,” which is hereby incorporated by reference in its entirety.
The present invention generally relates to an electrochemical battery cell. More particularly, the present invention relates to a compact, robust, multifunctional and highly manufacturable rechargeable battery cell.
Increasing the discharge capacity of electrochemical cells is an ongoing objective of manufacturers of electrochemical cells and batteries. Often there are certain maximum external dimensions that place constraints on the volume of a given type of cell or battery. These maximum dimensions may be imposed through industry standards or by the amount of space available in the device into which the cells or batteries can be put. Only a portion of the volume is available for the materials necessary for the electrochemical discharge reactions (electrochemically active materials and electrolyte), because other essential, but inert, components (e.g., containers, seals, terminals, current collectors, and separators) also take up volume. A certain amount of void volume may also be necessary inside the cells to accommodate reaction products and increases in material volumes due to other factors, such as Increasing temperature. To maximize discharge capacity in a cell or battery with a limited or set volume, it is desirable to minimize the volumes of inert components and void volumes.
Conventional battery cell designs incorporate a single open ended prismatic or cylindrical cell can and one matching cell end cap, used to hermetically seal the cell's internal components from the outside world. The construction and design of the cell's end cap and the manner in which it mounts to the cell's can directly effect how the cell is “activated,” or internally saturated with electrolyte, how the cell vents gas during an unsafe high pressure event, and how the cell's internal active materials are connected to its external power terminals.
A cylindrical cell is vented using a complex valve designed to initially cut off current flow when a certain internal pressure is reached and then ultimately open when the cell experiences a higher internal pressure threshold. When the valve actuates, the cell is usually considered unusable. Vent mechanisms in cylindrical cells tend to be “hidden” under the battery terminal so that they take up less space on the end cap. In addition to using up valuable cell volume that could otherwise be used for cell capacity, this results in a series of small vent “windows” in the end cap that are designed to allow gas to escape from during a high pressure event. Often, when a cell experiences this type of event, materials other than gas try to escape from the cell through this vent and end up clogging these windows. This defeats the purpose of the vent, preventing gas from escaping, and the cell ends up reaching critical internal pressures and often explodes.
A low inductance, easily manufacturable electrochemical cell is provided. In one or more embodiments, a cylindrical electrochemical cell can include a spirally wound assembly having an anode sheet and a cathode sheet separated by separator membranes, the cathode sheet having a first electroactive layer on a first current collector, and the anode sheet having a second electroactive layer on a second current collector, the spirally wound assembly having a cylindrical side wall and opposing end faces. At least one of the first current collector and the second current collector can be in electrical communication with conducting tabs that extend from the anode sheet or the cathode sheet, the conducting tabs extend from an end face of the spirally wound assembly. Centers of the conducting tabs can be located within a 90 degree quadrant of an end face of the spirally wound assembly.
Conventional battery cell end cap design incorporates one or more of a fill-hole, a safety vent, and a power terminal into the design of an end cap. These features are usually separate, individual, and bulky entities occupying their own internal volume on the cell's end cap. Battery cells that utilize a symmetrically centralized activation fill-hole have a distinct advantage during manufacture over cells whose activation fill holes are off center and require orientation during fill. Battery cells that utilize a symmetrically centralized battery terminal have a distinct advantage in commercial applications over cells whose power terminal is off center and require specific orientation during use and/or packaging into larger format strings of cells.
The internally active material of the cell includes two electrodes, a cathode and an anode. One contributor to the impedance of a battery cell is the lack of current carrying paths between the active cell materials (anode and cathode) and the external cell terminals. It has been surprisingly discovered that overall cell impedance can be significantly lowered by using more current carriers, or “tabs”, than conventional cylindrical (wound assembly) cells, whose designs call for one or two tabs per electrode. In one or more embodiments of the invention, a plurality of tabs are joined at a larger current collector on either side of the cell called an extension tab, which then makes the connection with each of the battery terminals of the cell. In one or more embodiments, the electrode can include about 4 to about 12 tabs, and for example, may include four tabs. In other embodiments, the electrode includes one tab per 200 cm2 area of electrode. High power battery cells will require a higher density of tabs than low power cells.
The tabbed electrodes are then organized into an electrochemical cell. A separator sheet, e.g., two separator sheets, is interposed between the cathode and anode sheets such that the tabs of the cathode and anode are located at opposite sides of the assembly. The multilayer assembly is spirally wound to form a spiral electrochemical assembly, known as a “jellyroll.” A jellyroll (8) with extended tabs (6), (7) is illustrated in FIG. 1.
The tabs can be of different length, which reflect their distances from the jelly role center when wound. The length of the tabs may be adjusted before or after winding the jellyroll. In order to form the tabbed electrode, a portion of the electroactive material is removed from an edge of the electrode to create a clean surface for electrical contact as shown in FIG. 6B (not drawn to scale). The tabs are electrically connected, e.g., by welding, riveting, crimping or other similar technique, to an exposed portion of the electrode. An exemplary method for cleaning the contact surfaces and attaching the collector tabs is provided in co-pending U.S. Provisional Patent Application No. 60/799,894 entitled “Use of a Heated Base to Accelerate Removal of Coated Electrode in the Presence of a Solvent,” filed on May 12, 2006, the contents of which are incorporated by reference. The tabs are then covered with a non-reactive tape (65), which covers the exposed metal tabs and prevents undesired chemical reactions with the cell chemicals. Tape (65) covers both sides of the electrode in the vicinity of the tabs. The tape covers that portion of the tab that lies over the electrode and may cover some or all of the underlying electrode that remains exposed, i.e., that is not covered by either active electrode layer or a current collecting tab. At least a portion of the tab that extends out from the electrode is not covered by tape.
In one aspect of the tab design, the thickness of the materials that make up the jellyroll is controlled. Each of the materials (anode electrode, cathode electrode, and separator) have thickness controlled to a very tight tolerance (approximately ±2 um each). This allows one to model and reliably predict exactly how these materials will spirally wind into a jellyroll, including the number of turns and the finished diameter. This permits the accurate location of the tabs within the jellyroll.
A third aspect of tab design is selection of the appropriate tab length and tab bending, as is illustrated in FIG. 7B. This is how the four tabs (61), (62), (63), (64) are captured and connected to the battery terminals. Step 1 of FIG. 7B shows the rolled top face of a battery and the location of all four tabs as they project from the face of the jellyroll. An insulation disc (3) is positioned over the end of the jellyroll, and the tabs are inserted through slots in the insulation disc. The insulation disc isolates each tab from the jellyroll. First all four tabs are bent towards the center axis (indicated by an “+” in FIG. 7B) of the jellyroll over an insulation disc (3). The result is a stack of tabs fanning in a region of up to about 140 degrees over of the face of the jellyroll. As noted previously, the tab length may vary. In one or more embodiments, the tab closest to the center axis, e.g., tab (64), is the shortest and the tab farthest from the center axis, e.g., tab (61), is the longest. The tab closest to the center of the jellyroll may be cut to a shorter length than the rest of the tabs, and each subsequent outwardly positioned tab is longer than the previous inner tab. The result is that when all four tabs are folded over, as illustrated in step 2 of FIG. 7, their ends align the same distance away from the axis of the jellyroll. Once the tabs are all laying flat, they are in the position that they will be in when the cell is finished. However, they must first be connected to the battery terminal's extension tab. In order to achieve this they are all bent together at about a 90° angle to the face of the jelly roll and parallel to and at the axis of the jellyroll, as illustrated in step 3 of FIG. 7. This consolidates the four tabs into one entity to which the battery terminal's extension tab can easily be welded.
FIGS. 10A and 10B illustrate tab position and current flow in a conventional wound cell. FIG. 10A views the rolled electrode from the rolled edge. FIG. 10B is a plan view of an unrolled electrode of the conventional cylindrically wound cell. In this wound cell, a single tab 1000 is placed at the end of an electrode, and current flows in the direction of 1010. When the cell is charged or discharged, current flow along the length of the electrode, leaving tab 1000 and traveling down the length of the electrode. When the electrode is rolled, as shown in FIG. 10A, current along the electrode flows in the counter-clockwise direction 1010. Therefore, the electrode acts as a coil, and the current that flows in the coil can induce a magnetic field along the along the axis of the coil, according to the well-known “right hand rule.” This can result in a relatively large inductance in the wound cell. When anode and cathode sheets are wound into a cylindrical jelly roll according to this conventional arrangement, two coils are created.
To demonstrate the invention, several cylindrical-wound cells were made. These cells were 26 mm in diameter and 65 mm long, so-called “26650-sized” cells. These cells were made with both four and eight tabs, evenly spaced along the length of the electrode. For comparison, commercially-available cylindrical-wound cells of similar capacity were obtained. All cells had their inductance measured using two methods: (1) Fluke PM6306 RCL meter; and (2) Solartron 1250 frequency response analyzer. Using the Solartron frequency response analyzer, it was that the cells with four tabs had an average inductance of 0.025 microH using the Solartron. The cells with eight tabs had an average inductance of 0.028 microH. In contrast, the commercially-available high-power cells with only one tab had an average inductance more than ten times larger (see Table 1 below).
Instrument: Fluke PM6306 RCL meter; 2.0 V AC excitation; Inductance
zero trim set at each (microH)
Cell Type frequency Instrument:
cell_ID cell inductance (microH) at freqency, kHz (2.0 V AC excitation) Solartron 1250 no. of
All cells: TX-C-1 26650s 1 4 10 25 50 100 FRA, 5 mV tabs
4a5 nm 0.03 0.05 0.01 0.02 0.03 4
3a1 nm 0.04 0.06 0.05 0.03 0.01 4
3a2 0.02 0.06 0.04 0.02 0.02 0.02 4
3a3 nm 0.06 0.04 0.03 0.03 0.03 4
4a1 nm 0.06 0.05 0.02 0.03 0.02 0.024 4
4a4 nm 0.06 0.05 0.04 0.03 0.03 0.026 4
4b6 nm 0.06 0.05 0.02 0.03 0.02 0.029 8
4b4 nm 0.07 0.05 0.04 0.03 0.03 0.026 8
Sony 18650VT 0.50 0.68 0.433 1
Sanyo 18650 LCO regular 0.45 0.61 0.330 1
Sony 18650VT 0.36 0.63 0.336 1
Valence 18650 IFR13N5 0.48 0.65 0.385 1
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U.S. Classification 429/3, 29/623.1, 429/94
International Classification H01M4/04, H01M14/00, H01M4/00
Cooperative Classification Y10T29/49108, H01M10/0431, H01M2/263
European Classification H01M10/04D, H01M2/26C
Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:CHU, ANDREW;GOZDZ, ANTONI;RILEY, GILBERT;AND OTHERS;REEL/FRAME:019776/0278;SIGNING DATES FROM 20070724 TO 20070731
Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:CHU, ANDREW;GOZDZ, ANTONI;RILEY, GILBERT;AND OTHERS;SIGNING DATES FROM 20070724 TO 20070731;REEL/FRAME:019776/0278