PATENT DOCUMENT

Publication Number: US-10439187-B2
Application Number: US-201715644311-A
Country: US
Kind Code: B2

Title: Laminar battery system

Abstract:
A battery system comprises a plurality of substantially planar layers extending over transverse areas. The plurality of layers comprises at least one cathode layer, at least one anode layer, and at least one separator layer therebetween.

Claims:
We claim: 
     
       1. A battery assembly, comprising:
 a first anode current collector; 
 first anode active material coupled to the first anode current collector; 
 a first cathode current collector; 
 first cathode active material coupled to the first cathode current collector; 
 a first separator positioned between the first anode active material and the first cathode active material; 
 a second anode current collector positioned adjacent the first cathode current collector without anode active material positioned therebetween; 
 second anode active material coupled to the second anode current collector; 
 a second cathode current collector; 
 second cathode active material coupled to the second cathode current collector; and 
 a second separator positioned between the second anode active material and the second cathode active material. 
 
     
     
       2. The battery assembly of  claim 1 , wherein the battery assembly has a thickness less than 100 microns. 
     
     
       3. The battery assembly of  claim 1 , further comprising a spacer positioned between the second anode current collector and the first cathode current collector. 
     
     
       4. The battery assembly of  claim 1 , wherein the battery assembly has a cathode active material stacking efficiency of at least about 30% of a thickness of the battery assembly. 
     
     
       5. The battery assembly of  claim 1 , further comprising an encapsulant that at least partially encapsulates the first anode current collector, the first anode active material, the first cathode current collector, the first cathode active material, the first separator, the second anode current collector, the second anode active material, the second cathode active material, and the second separator. 
     
     
       6. The battery assembly of  claim 5 , wherein portions of the first anode current collector, the first cathode current collector, and the second anode current collector extend through the encapsulant. 
     
     
       7. The battery assembly of  claim 1 , wherein the first anode current collector and the second anode current collector extend from a surface of the battery assembly and the first cathode current collector and the second cathode current collector extend from an opposing surface of the battery assembly. 
     
     
       8. A battery core, comprising:
 a first anode current collector with first anode active material coupled thereto; 
 a cathode current collector with cathode active material coupled thereto; 
 a separator positioned between the first anode active material and the cathode active material; and 
 a second anode current collector with second anode active material coupled thereto positioned adjacent the cathode current collector without anode active material positioned between the second anode current collector and the cathode current collector. 
 
     
     
       9. The battery core of  claim 8 , wherein the separator covers multiple surfaces of the cathode active material. 
     
     
       10. The battery core of  claim 8 , wherein the separator has sloped sides. 
     
     
       11. The battery core of  claim 8 , further comprising an ion transport layer positioned between the second anode current collector and the cathode current collector. 
     
     
       12. The battery core of  claim 8 , wherein the cathode active material has a thickness of approximately 10-30 microns. 
     
     
       13. The battery core of  claim 8 , wherein the battery core has an anode active material stacking efficiency of at least about 30% of a thickness of the battery core. 
     
     
       14. The battery core of  claim 8 , wherein the battery core has a thickness less than 50 microns. 
     
     
       15. A battery, comprising:
 first and second cells each comprising:
 an anode current collector; 
 anode active material coupled to the anode current collector; 
 a cathode current collector; 
 cathode active material coupled to the cathode current collector; and 
 a separator positioned between the anode active material and the cathode active material; and 
 
 an insulating spacer; wherein the first and second cells are coupled such that: 
 the cathode current collector of the first cell is positioned adjacent the anode current collector of the second cell; and 
 the insulating spacer is positioned between the cathode current collector of the first cell and the anode current collector of the second cell. 
 
     
     
       16. The battery of  claim 15 , further comprising a coating of rubber, silicone, or polymer that at least partially surrounds the first and second cells. 
     
     
       17. The battery of  claim 15 , wherein the cathode active material comprises at least 40% of a thickness of the battery. 
     
     
       18. The battery of  claim 15 , further comprising an electrolyte positioned between the cathode current collector of the first cell and the anode current collector of the second cell. 
     
     
       19. The battery of  claim 15 , further comprising a third cell coupled to the second cell wherein the cathode current collector of the second cell is positioned adjacent the anode current collector of the third cell. 
     
     
       20. The battery of  claim 15 , wherein the cathode current collector of the first cell is separated from the anode current collector of the second cell. 
     
     
       21. The battery of  claim 15 , wherein the cathode active material is thicker than the anode active material.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application is a continuation of U.S. patent application Ser. No. 14/041,843, filed Sep. 30, 2013, entitled “Laminar Battery System,” which claims the benefit under 35 U.S.C. § 119(e) of U.S. Provisional Patent Application No. 61/730,402, filed Nov. 27, 2012, entitled “Laminar Battery System,” the contents of which are incorporated by reference as if fully recited herein. 
    
    
     TECHNICAL FIELD 
     The subject matter of this disclosure relates generally to electronic devices, and specifically to battery systems for portable electronics and mobile devices. In particular, the disclosure relates to battery systems with particular energy density, form factor and overall size and weight requirements. 
     BACKGROUND 
     Batteries come in a range of different architectures and forms, including traditional rod-and-tube (dry cell) and flat plate (flooded cell) designs, as well as “jelly roll” configurations in which the anode and cathode layers are laid down on opposite sides of a flat sheet or flexible substrate and rolled up for insertion into the battery case or pouch. In flat battery designs, the rolled anode and cathode structure is folded into a low-profile casing or pouch, which is sealed along one or more sides. 
     Battery configurations for portable electronics and mobile devices require a range of design tradeoffs, including size, weight, power consumption, manufacturability, durability and thermal loading. In general, the amount of energy or storage capacity per battery weight (or volume) can also be an important factor, because a greater energy/battery weight or volume ratio makes for a better, longer lasting battery 
     SUMMARY 
     Exemplary embodiments of the present disclosure include battery systems, and methods of making the battery systems. The battery systems may comprise a plurality of substantially planar layers extending over a transverse area. The plurality of layers may include at least one cathode layer, at least one anode layer, and at least one separator layer therebetween. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a battery with increased energy density and improved form factor. 
         FIG. 2  is a cross-sectional view of the battery. 
         FIG. 3  is an enlarged cross-sectional view of the battery, showing the laminar structure of the battery core. 
         FIG. 4  is an alternate cross sectional view of the battery, showing the laminar core structure in an alternating anode/cathode layer configuration. 
         FIG. 5  is a schematic diagram of a method for producing a laminar battery core. 
         FIG. 6A  is a cross-sectional illustration of a cathode layer for a laminar battery core. 
         FIG. 6B  is a cross-sectional illustration of anode and cathode layers for the laminar battery core. 
         FIG. 6C  is a cross-sectional illustration of a core stack element for the laminar battery core, with anode and cathode layers, anode collector and flexible sealant. 
         FIG. 7A  is a schematic illustration of the laminar battery core stack, illustrating different external connector configurations. 
         FIG. 7B  is a schematic illustration of the laminar battery core stack, in a single-side stack configuration. 
         FIG. 7C  is a schematic illustration of the single-side stack configuration, illustrating representative layer thicknesses. 
         FIG. 8  is a schematic illustration of the laminar battery core stack, in a double-sided configuration. 
         FIG. 9  is a schematic illustration of the laminar battery core stack, in a single-sided, double stack configuration. 
         FIG. 10  is a schematic illustration of the laminar battery core stack, in a multi-stack configuration. 
     
    
    
     DETAILED DESCRIPTION 
       FIG. 1A  is a perspective view of battery assembly  10  with pouch or outer casing  12  and protective wrap or film  14 , which may be used for shipping, or for protection from damage and corrosion. An encapsulant or other sealing material  16  may be utilized to seal battery casing  12  to prevent leakage of electrolytes and other materials from the inside of battery assembly  10 , to inhibit moisture intrusion, and to reduce oxidation and corrosion of the anode and cathode surfaces. 
     In the particular configuration of  FIG. 1 , battery assembly  10  has a substantially oblong or rectangular geometry or form factor, with width W defined between opposite sides  18 A and  18 B, length L defined between opposite sides or ends  19 A and  19 B, and thickness T defined between opposite major surfaces  20 A and  20 B. The battery core is provided within casing  12 , and is configured for increased energy density, as described below, within an improved form factor (or volume envelope), as defined by length L, width W and thickness T. 
     Length L and width W are typically measured along first and second major surfaces  20 A and  20 B of battery system  10 , in the direction of (horizontal) axes x and y, excluding the thickness of protective wrapper or film  14 . Similarly, height or thickness T is measured between major surfaces  20 A and  20 B, along (vertical) axis z, also excluding protective wrapper  14 . 
     In low-profile or flat configurations of battery assembly  10 , thickness T is generally less than length L or width W, so that major surfaces  20 A and  20 B have substantially greater surface area than side and end surfaces  18 A,  18 B.  19 A and  19 B. The orientation of coordinate axes x, y, and z is arbitrary, however, and the various dimensions of length L, width W, and thickness T may also be interchanged, depending on configuration. 
     Connector  22  provides electrical power and signal connections to battery assembly  10 , for example in a “pig tail” configuration with a connector board  23  coupled to battery assembly  10  via flex circuit  24 , as shown in  FIG. 1 . Depending on application, connector  22  and flex circuit  24  may be configured to accommodate a range of different connection geometries, for example along a side surface (e.g., side  18 A or  18 B) or an end surface (e.g., end  19 A or  19 B) of battery casing  12 , or at a corner interface (e.g., between side  18 A and end  19 A, as shown in  FIG. 1 ). 
     Where battery dimensions including length L, width W, and thickness T are constrained, increased energy density provides battery system  10  with greater storage capacity within a given form factor, and longer service life between charges. Increased energy density also allows for reducing the form factor at a given storage capacity, or a combination of increased capacity and reduced battery dimensions, for overall improvements in both battery life and form factor or size envelope. 
       FIG. 2  is a cross-sectional view of battery system (battery assembly or battery)  10 , taken along line  2 - 2  of  FIG. 1 . Battery case or pouch  12  is formed about inner battery element or core  28 , which stores electrical energy and provides voltage and current. Protective wrapper  14  may be formed of an thin polymer sheet, for example a polyethylene terephthalate (PET) film, and provided to cover battery  10  during shipping, for example utilizing insignia  14 A for identification. 
     Battery casing  12  is typically formed of a laminated material, for example an aluminum alloy core layer  12 A with plastic or polymer insulating layers  12 B and  12 C on the inner and outer surfaces. Typically, core layer  12 A provides strength, durability and structural integrity, and while coating layers  12 B and  12 C provide electrical insulation and chemical protection from caustic materials in battery core  28 , for example acid or alkali electrolytes or other active components  28 A. Alternatively, battery casing  12  may be formed of a polymer material, or using an encapsulant, conformal coating or sealant material, for example as described with respect to sealing material  16 . 
     Battery core  28  comprises a laminated structure, as shown in  FIG. 2 , with active materials  28 A interspersed between inactive or passive materials  28 B. Active materials  28 A include at least one or both of the cathode and anode layers, as described in more detail below. Inactive materials  28 B may include spacers, insulators or substrate materials, which separate the anode and cathode pads. Although three layers of active material  28 A and two spacer layers  28 B are shown, the number of individual layers varies, depending on the design of battery system  10  and battery core  28 , and additional or fewer layers are contemplated. 
     To improve the energy density and storage capacity of battery system  10 , battery core  28  is provided with an improved laminated structure to increase the relative volume of active materials  28 A, as compared to inactive or passive (spacer) materials  28 B. This also contrasts with rolled battery core designs, for example, where there are substantial side roll regions, with relatively low energy density. In the laminar structure of battery core  28 , on the other hand, active and passive layers  28 A and  28 B are substantially planer across most or substantially of the full length and width (that is, transverse area) of battery core  38 , including end regions  30 . 
     This laminar and substantially planar configuration for battery core  28  substantially reduces spacing issues presented by building anode and cathode layers into a rolled core configuration, where (1) there is a substantial amount of side roll that does not significantly contribute to battery capacity, and (2) there is a substantial spacing between the anode and cathode pads, which is required to prevent shorting in the high curvature side roll regions. 
     In contrast, active and passive layers  28 A and  28 B of battery core  28  are substantially flat and planar across substantially the full length and width of battery assembly  10 , as shown in  FIG. 2 , increasing capacity by providing relatively more substantially planar area in battery core  28 , with relatively higher energy density and more efficient energy storage. The substantially planar, laminar configuration of battery core  28  also reduces the non-planar side roll areas, as provided in a rolled core design, and which have relatively lower energy density and relatively less efficient energy storage. These effects may be particularly relevant in flat-profile form factor designs, as shown in  FIGS. 1 and 2 , where the side roll curvature is high, and only the relatively straight or planar portions of the battery core significantly contribute to overall battery capacity and storage capability. 
     Laminar, substantially planar battery core  28  also reduces the required spacing between the anode and cathode pads, because tolerance is easier to maintain across the flat-plane structure of active and passive material layers  28 A and  28 B, as compared to a rolled design, with reduced risk of the anode and cathode pads accidentally touching, and shorting out the battery. This also increases energy storage density, by providing more active material  28 A per unit volume of battery core  28 , including relatively more cathode thickness or volume, as compared to passive material  28 B. 
       FIG. 3  is an enlarged cross-sectional view of battery  10 , showing the internal laminar structure of battery core  28 . As shown in  FIG. 3 , battery core  28  is formed with alternating layers of active material  28 A and passive materials  28 B, for example insulators or substrates, positioned between upper and lower portions of battery casing  12 , and encapsulated with an epoxy, polymer, or other encapsulating material  16 . 
     Battery casing  12  provides a mechanical, electrical and chemical barrier to isolate battery core  28  of battery  10 , as described above. Depending on embodiment, battery casing  12  may extend along the sides of battery core  28 , as shown in  FIGS. 1 and 2 , or encapsulating material  16  may be exposed on the sides, as shown in  FIG. 3 . Encapsulating material  16  may also be provided in a range of different thicknesses, and applied either across the full height or thickness of battery core  28 , as shown on the left side of  FIG. 3 , or distributed across individual layers  28 A of active material, as shown in the right side of  FIG. 3 . 
     Active material  28 A is formed of anode layers  32  and cathode layers  34 , spaced apart by separator layers  36 . Pads or conductor (collector) layers  37  and  39  are provided adjacent anode and cathodes  32  and  34 , respectively. As shown in  FIG. 3 , the top and bottom anode/cathode structures have an inverted or double-sided stack orientation, with adjacent cathode layers  34  separated by a single anode pad layer  39 . 
     Thus, three layers of active material  28 A are shown, including two anode layers  32  and two cathode layers  34 , separated by two spacer layers  36 . Alternatively, additional or fewer anode, cathode, spacer, and collector layers  32 ,  34 ,  36 ,  37 , and  39  may be included. In additional configurations, collector layers  37  and  39  may be defined as either active or passive material, in which case the example of  FIG. 3  could be considered to have three or four active layers  28 A, and two or three passive or inactive layers  28 B. 
     Anode layers  32  and cathode layers  34  are formed of suitable anode and cathode materials including, but not limited to, lithium cobalt oxide, lithium iron phosphate, lithium manganese oxide, lithium, lithium metal phosphates, carbon, and graphite, for example graphite infused with lithium ions. In one particular configuration, for example, anode layer  32  is formed of lithium, and cathode layer  34  is formed of lithium cobalt oxide. Alternatively, anode layer  32  may be formed of lithium cobalt oxide, or another lithium or metal oxide material, and cathode layer  34  may be formed of graphite. Depending on the charging or discharging state of battery  10 , moreover, charge flow in anode and cathode layers  32  and  34  may reverse, as described below, without loss of generality. 
     Separator layer  36  is formed of a suitable insulating separator material that is permeable to ion transport, for example a porous polymer or microporous polyethylene lithium ion transport material, or a paper or fibrous composite material. 
     Anode and cathode pads or collector layers  37  and  39  may be formed of suitable conducting metals such copper or aluminum. Alternatively, the lithium anode may be utilized, at least charge transport inside batter core  28 . 
     Separator layer  36  may be permeated with an electrolyte having suitable ion transport properties, for example ethylene carbonate or diethyl carbonate containing lithium ion complexes. In lithium and lithium ion applications of battery  10 , the electrolyte is typically non-aqueous, in order to avoid reacting with any lithium metal components of battery core  28 . 
     Carbon nanotube materials may also be used, for example extending from the anode base (layer  32  or  37 ), so that lithium ions are maintained by attachment to the (conducting) carbon nanotube material. This contrasts with other designs, were lithium may be eaten away or otherwise lost from anode layer  32  or anode collector (or pad  37 ), raising the risk of a short or other battery fault. Where a sufficient level of lithium is maintained, using carbon nanotubes or other lithium retention elements in one or both of anode layer  32  and anode collector layer  37 , battery  10  remains effective over periods of extended use, including repeated charge and drain cycles. 
     In discharge operations of battery  10 , for example oxidation may take place in anode layer  32 , so that anode layer  32  functions as a negative electrode. Thus, anode collector  37  may have a relatively negative charge, providing electron flow to the external circuit. Reduction reactions may take place in cathode layer  34 , so that cathode layer  34  functions as a positive electrode. Thus, cathode collector  39  may have a relatively positive charge, accepting electron flow from the external circuit. In secondary battery systems  10 , recharging operations may be supported, where the current flow and oxidation reduction reactions are reversed. The charge flow in (or designations of) anode layer  32  and cathode layer  34  may also be reversed, depending on usage and nomenclature, and as described above. 
       FIG. 4  is an alternate cross-sectional view of battery  10 , showing the internal laminar structure of battery core  28  in a non-inverted or single-sided stack configuration. In this design, anode layers  32  and cathode layers  34  alternate across the height of battery  10 , between top and bottom battery casings  12 . An additional insulating spacer layer  40  is provided between adjacent anode carrier layer  37  and cathode carrier layer  39 . Again, the number of individual layers is arbitrary, and may be increased or decreased depending on layer thickness, battery configuration, and battery form factor. 
     The design of  FIG. 4  has a substantially uniform layering configuration, with separate anode and cathode carrier layers  37  and  39  for each anode layer  32  and cathode layer  34 , respectively. An additional spacer, insulator, or insulating substrate layer  40  may be included, adding to the relative volume of passive material layers  28 B, but any such increase may be relatively nominal because the planar structure of battery core  28  does not require additional spacing tolerance to accommodate high curvature end regions, as characteristic of rolled battery core designs. 
     For example, in some rolled battery core designs, a minimum tolerance of about 20 microns or more is required between adjacent anode and cathode pads or carrier layers  37  and  39 , in order to reduce the risk of shorting in end-roll regions with high curvature. In other designs, the required tolerance may be even greater, for example more than about 50 microns, or even more than about 100 microns. In the substantially planar configuration of battery core  28 , however, there is little or substantially no curvature, and the minimum required thickness for inter-pad (insulation) layer  40  may be less than 20 microns, for example about 10 microns or less, or about 8 microns or less. 
       FIG. 5  is a schematic diagram of method  50  for producing a laminar battery core, for example laminar core  28  of battery assembly  10 , as shown in  FIGS. 1-4 , and as described above. Method  50  includes one or more steps selected from deposition (step  51 ), baking or annealing (step  52 ), encapsulation (step  53 ), adding electrolyte and separator (step  54 ), and completing the battery core or core stack element (step  55 ). 
     Deposition (step  51 ) may include depositing an anode slurry on an anode collector or anode collector substrate, depositing a cathode slurry on a cathode collector or cathode collector substrate, or both. The lateral dimensions of the deposited anode and cathode materials may be defined by positioning a screen or electrode mask with respect to the collector substrates. The thickness or depth d of the anode and cathode layers may be controlled by translating a silkscreen blade or other mechanical element across the mask or screen, as illustrated in step  51  of  FIG. 5 . 
     Baking/Annealing (step  52 ) may include heating the mask or masks with the anode or cathode slurry materials in order to anneal or harden the materials into a suitable form for use in a battery or battery core stack. Depending on embodiment, a nickel iron alloy such as INVAR or KOVAR may be utilized for the mask, or another material with a low or particularly selected (matched) coefficient of thermal expansion (CTE), in order to maintain particular dimensions with respect to the anode and cathode material during the heating in step  52 , and in any subsequent cooling process. 
     Encapsulation (step  53 ) may include removing the electrode mask and positioning a secondary or encapsulation mask with respect to the anode or cathode layers, and/or the corresponding collector substrates. An encapsulant such as a thermoplastic or other polymer may then be deposited about the anode and cathode layers based on the encapsulation mask geometry. The encapsulant may be cured by heating, ultraviolet radiation, or chemical means. Alternatively, a self-curing encapsulant compound may be utilized, for example an epoxy resin. 
     Electrolyte and separator components are added in step  54 . For example, a permeable separator material may be applied to either or both of the anode or cathode layer, and the separator material may be saturated or permeated with an electrolyte material. Additional encapsulant may also be applied along the separator layer. 
     In step  55 , the anode and cathode layers are joined in an adjacent relationship to form a laminated battery core element, with the electrolyte-permeated separator positioned between adjacent anode and cathode layers, and the electrode and cathode collector layers positioned on the electrode and cathode layers, respectively. In general, the collector layer may be positioned opposite the separator layer, as defined across the respective anode and cathode layers. 
     The individual core stack elements can be assembled in a variety of different configurations to form the battery core, for example as described above with respect to  FIGS. 3 and 4 , above, and in  FIGS. 6A-6C, 7A-7C, and 8-10 , below. Suitable techniques include, but are not limited to, optical positioning, robotic positioning, optical device assembly techniques, and other suitable positioning techniques for assembly battery core or core stack  28 . 
     The laminated core structure of battery  10  and method  50  provides a more uniform battery core structure than a rolled battery design, with more precise control of critical dimensions including individual layer thicknesses. By reducing thickness requirements in the separator and other passive or inactive components, moreover, energy density is increased, for improved performance within a given form factor or volume envelope. 
     Battery lamination method  50  also provides a greater selection range for individual (active and passive) layer thicknesses, including thicker active anode and cathode layers. In thicker and “superthick” embodiments, the battery core is more “z efficient,” with a higher density of active materials along the vertical (thickness) dimension of the battery core, perpendicular to the individual layers, and between the major surfaces in a flat profile battery design. 
     Limitations on layer thickness are primarily based on manufacturing considerations, and mask-to-mask (or roll to roll) variations. There may also be a relationship between anode and cathode thickness and ion transport capability. Where thicker anode and cathode layers may be achieved by silk screening or other lamination methods  50 , edge deterioration effects may be mitigated using a conformal coating or encapsulant to seal the edges of the battery core, as described above. 
       FIG. 6A  is a cross-sectional illustration of cathode layer  34  for a laminar battery core, for example battery core  28  of  FIGS. 1-4 . A relatively thick layer of cathode material  34  is deposited on cathode substrate  39 , for example lithium cobalt oxide material using a masking or screening process, as described above, or via another process such as sputtering or chemical vapor deposition (CVD). Encapsulant or conformal coating material  16  may be applied to seal the sides or edges of cathode layer  12 . 
     A separator/electrolyte or ion transport layer  36  can be deposited on top of cathode layer  34 , opposite cathode substrate layer  39 . Depending upon application, a lithium phosphate, lithium phosphorous, or lithium phosphorous oxynitride (LiPON or LiPO x N y ) material may be utilized for separator layer  36 , for example to replace the traditional lithium ion transfer electrolyte and separator material with a glassy or thin film solid electrolyte separator layer  36 . In additional configurations, a lithium polymer battery configuration may be utilized, using a lithium-salt type electrolyte in a substantially solid polymer composite for separator layer  36 . 
       FIG. 6B  is a cross-sectional illustration of anode and cathode layers  32  and  34  for laminar battery core  28 . Anode layer  32  is formed on separator layer  36 , opposite cathode layer  34 , for example by physical vapor deposition (PVD) or powder deposition of a lithium material. Alternatively, anode layer  32  may be formed of different material such as graphite, and anode layer  32  may be applied via a screening or masking method, for example as described above with respect to method  50  of  FIG. 5 . 
       FIG. 6C  is a cross-sectional illustration of battery core element  60 , including anode and cathode layers  32  and  34  separated by separator layer  36 . Battery core element  60  also includes anode and cathode collector layers  37  and  39 , as positioned adjacent to and in electrical contact with anode and cathode layers  32  and  34 , respectively, opposite separator layer  36 . Encapsulant or conformal coating  16  and flexible sealant  62  are provided to seal the sides of battery core element  60 , including cathode layer  32 , separator layer  36 , and anode layer  32 . 
     Flexible sealant  60  may be formed of an insulating material such as a room temperature vulcanizing (RTV) silicone or other silicone or polymer-based material, or an encapsulant or conformal coating. Similar, encapsulant  16  may be formed of a flexible sealant, such as RTV silicone or other silicone or polymer based material. 
       FIG. 7A  is a schematic illustration of core stack element  60 , illustrating different external connector configurations. As shown in  FIG. 7A , anode collector  37  may extend to external connection point  37 A on the same side of stack element  60  as cathode collection point  39 A, as defined for cathode collector  39 . Alternatively, anode collector  37  may extend to external connection point  37 B, on the opposite side of stack element  60  with respect to cathode collection point  39 A. 
       FIG. 7B  is a schematic illustration of battery core  28 , in a single-side stack configuration. In this configuration, individual stack elements  60  are stacked together in the same orientation, with anode collectors  37  extending to anode connection points  37 B along one side of battery core (or stack)  28 , and cathode collectors  39  extending to cathode connection points  39 A on the opposite side of battery core (or stack)  28 . This allows all the cathode lines to be coupled to a single cathode output, and all the anode lines to be coupled to a single anode output, thus making the battery have a single cathode and a single anode. 
       FIG. 7C  is a schematic illustration of battery core  28  in the single-stack configuration, illustrating representative layer thicknesses (in microns). In this particular configuration, cathode layer  34  has a thickness of about 10 microns, or about 25% of the total stack thickness of about 40 microns, including two conformal coating or encapsulation layers  16  of about 3 microns each, anode and cathode collector layers (or substrates)  37  and  39  of about 8 microns each, separator layer  36  of about 2 microns, and anode layer  32  of about 6 microns. 
     This results in a net or average cathode stacking efficiency of about 25% or more for battery core (or stack)  28 , as defined by the fraction of the battery thickness occupied by cathode layers  34 . This result is substantially higher than in other battery designs, providing battery core  28  (and battery  10 ) with greater energy storage density and capacity. In thicker embodiments, cathode layer  34  may have a thickness of up to 25 microns or more, or more than 40% of the total stack thickness, for example about 45% of the total stack thickness. 
       FIG. 8  is a schematic illustration of battery core (or core stack)  28  in a double-sided stack configuration. In this example, one core or stack element  60  is inverted with respect to the other, as described above with respect to  FIG. 3 , using a single cathode collector  39  between two adjacent cathode layers  34 . In this configuration, the vertical cathode efficiency may be about 30% or more (about 30.3%), based on two cathode layers  34  with a total thickness of about 20 microns, in a stack with two anode layers  34  at about 6 microns each, two separator layers  36  at about 2 microns each, two conformal coating layers  16  at about 3 microns each, two anode collectors  37  at about 8 microns each, and only one cathode collector  39  at about 8 microns (about 66 microns total). For thicker cathode designs of up to 25 microns or more, the cathode stacking efficiency may be higher, for example about 50% or more. 
       FIG. 9  is a schematic illustration of battery core or stack  28  in a single-sided, double stack configuration. This is similar to the example of  FIG. 8 , but with stack elements  60  inverted so that a single anode collector  37  is positioned between two adjacent anode layers  32 . The relative stacking thicknesses are approximately the same, as described above with respect to  FIG. 8 , resulting in a vertical cathode stacking efficiency of about 30% (or 30.3%) 
       FIG. 10  is a schematic illustration of battery core or stack  28 , in a multi-stack configuration. In this particular example, battery stack  28  includes two separate instances of the single-sided, double stack configuration of  FIG. 9 . Alternatively, battery stack  28  may comprise one, two, three, four or more core stack elements, using any of the stacking configurations shown in  FIG. 3, 4, 7A-7C, 8 , or  9 . 
     The foregoing description, for purposes of explanation, used specific nomenclature to provide a thorough understanding of the invention. However, it will be apparent to one skilled in the art that the specific details are not required in order to practice the invention. In other instances, well known circuits and devices are shown in block diagram form in order to avoid unnecessary distraction from the underlying invention. Thus, the foregoing descriptions of specific embodiments of the present invention are presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise forms disclosed, obviously many modifications and variations are possible in view of the above teachings. The embodiments were chosen and described in order to best explain the principles of the invention and its practical applications, to thereby enable others skilled in the art to best utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated. It is intended that the scope of the invention be defined by the following claims and their equivalents

Metadata:
Filing Date: 20170707
Publication Date: 20191008
Grant Date: 20191008
Priority Date: 20121127
Inventors: ANASTAS, GEORGE V.
SPRINGER, GREGORY A.
RECTOR, III, JACK B.
FUNAMURA, Joshua R.
SILZ, Kenneth M.
Assignee: APPLE INC
CPC Classifications: [{"code": "H01M4/0471", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01M50/417", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01M10/0562", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01M10/052", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01M10/0562", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01M2300/002", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01M2004/021", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T29/49108", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01M4/0421", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01M6/40", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T29/49115", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01M4/0421", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01M10/0585", "inventive": true, "first": false, "tree": "[]"}, {"code": "Y10T29/49115", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T29/49108", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01M6/40", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01M4/0404", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01M10/052", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01M4/0471", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01M2004/021", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01M10/0585", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01M2300/002", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T29/49108", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01M10/0562", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01M6/40", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T29/49115", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01M10/052", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01M2/1653", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01M2/145", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01M4/0421", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01M4/0404", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01M4/0471", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01M10/0585", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01M2004/021", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01M2300/002", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01M50/417", "inventive": true, "first": false, "tree": "[]"}, {"code": "Y02P70/50", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01M4/0404", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01M50/403", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01M50/403", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y02E60/10", "inventive": false, "first": false, "tree": "[]"}]
Family ID: 50773573