PATENT DOCUMENT

Publication Number: US-11404682-B2
Application Number: US-201715833106-A
Country: US
Kind Code: B2

Title: Non-rectangular shaped electrodes utilizing complex shaped insulation

Abstract:
The disclosed technology relates to electrodes of a battery cell. The electrodes include a current collector having a first non-rectangular shape, an active coated region having a second non-rectangular shape, an insulator coated region having a third non-rectangular shape, and an uncoated tab disposed adjacent to the insulator coated region. The insulator coated region is disposed along a periphery of the current collector along a plurality of sides or edges of the current collector providing several locations for the tab to be positioned.

Claims:
What is claimed is: 
     
       1. An electrode, comprising:
 a current collector having a first non-rectangular shape, the current collector comprising a first planar surface and a second planar surface, the second planar surface disposed opposite the first planar surface; 
 an active coated region disposed on a portion of the first planar surface, the active coated region having a second non-rectangular shape; 
 an insulator coated region consisting of a non-conductive insulation material disposed on a portion of the first planar surface to prevent an electrical short with an adjacent electrode, the non-conductive insulator coated region having a third non-rectangular shape; and 
 a tab extending directly from the non-conductive insulator coated region, the tab comprising an uncoated region of the current collector, wherein the non-conductive insulator coated region extends contiguously across the tab, and wherein the first non-rectangular shape of the current collector comprises nine sides, the second-nonrectangular shape of the active coated region comprises eight sides, and the third non-rectangular shape of the insulator coated region comprises ten sides. 
 
     
     
       2. The electrode of  claim 1 , wherein the first non-rectangular shape is different from the second non-rectangular shape and the third non-rectangular shape. 
     
     
       3. The electrode of  claim 1 , wherein the second non-rectangular shape is different from the first non-rectangular shape and the third non-rectangular shape. 
     
     
       4. The electrode of  claim 1 , wherein the third non-rectangular shape is different from the first non-rectangular shape and the second non-rectangular shape. 
     
     
       5. The electrode of  claim 1 , wherein the portion of the active coated region is separate from the portion of the insulator coated region. 
     
     
       6. The electrode of  claim 1 ,
 wherein the portion of the insulator coated region is disposed along a periphery of the current collector; and 
 wherein at least three portions along the periphery of the current collector are not coated with an active electrode coating. 
 
     
     
       7. The electrode of  claim 6 , wherein the periphery comprises a first, second, third and fourth side of the current collector, the first side abutting the second side, the second side abutting the third side, and the third side abutting the fourth side. 
     
     
       8. The electrode of  claim 7 , wherein the tab is disposed on the first side. 
     
     
       9. The electrode of  claim 7 , wherein the tab is disposed on the second side. 
     
     
       10. The electrode of  claim 7 , wherein the tab is disposed on the third side. 
     
     
       11. The electrode of  claim 7 , wherein the tab is disposed on the fourth side. 
     
     
       12. The electrode of  claim 1 , wherein the second planar surface comprises:
 an active coated region disposed on a portion of the second planar surface, the active coated region having the second non-rectangular shape; and 
 an insulator coated region disposed on a portion of the second planar surface, the insulator coated region having the third non-rectangular shape. 
 
     
     
       13. A battery cell, comprising:
 a plurality of layers, wherein the plurality of layers comprise an anode, a separator, and a cathode; 
 an enclosure enclosing the plurality of layers; and 
 a first and second conductive tab extending from the enclosure, the first conductive tab coupled to the anode and the second conductive tab coupled to the cathode;
 wherein the anode and cathode each comprise:
 a current collector having a first non-rectangular shape, each current collector comprising a first planar surface and a second planar surface, the second planar surfaces disposed opposite the first planar surfaces; 
 an active coated region disposed on a portion of each of the first planar surfaces, the active coated regions each having a second non-rectangular shape; 
 an insulator coated region consisting of a non-conductive insulation material disposed on a portion of each of the first planar surfaces to prevent an electrical short with an adjacent electrode, the non-conductive insulator coated regions each having a third non-rectangular shape; and 
 a tab extending directly from the non-conductive insulator coated regions, the tab comprising an uncoated region of the current collector, wherein the non-conductive insulator coated region extends contiguously across the tab, wherein the first non-rectangular shape of the current collector comprises nine sides, the second-nonrectangular shape of the active coated region comprises eight sides, and the third non-rectangular shape of the insulator coated region comprises ten sides. 
 
 
 
     
     
       14. The battery cell of  claim 13 , wherein the first conductive tab is coupled to the tab of the anode; and wherein the second conductive tab is coupled to the tab of the cathode. 
     
     
       15. The battery cell of  claim 13 ,
 wherein the portions of the insulator coated regions are disposed along a periphery of the current collectors; and 
 wherein at least three portions along the periphery of the current collectors are not coated with an active electrode coating. 
 
     
     
       16. The battery cell of  claim 15 , wherein the periphery comprises a first, second, third and fourth side of each of the current collectors, the first side abutting the second side, the second side abutting the third side, and the third side abutting the fourth side. 
     
     
       17. The battery cell of  claim 13 , wherein the second planar surfaces each comprise:
 an active coated region disposed on a portion of each of the second planar surfaces; and 
 an insulator coated region disposed on a portion of each of the second planar surfaces. 
 
     
     
       18. A method for creating a plurality of electrodes, the method comprising:
 applying an active coating on a current collector in a non-rectangular shape; 
 applying an insulator coating in a complex shape, the insulator coating consisting of a non-conductive insulation material disposed adjacent to the active coating to prevent an electrical short; and 
 creating a plurality of electrodes from the current collector, each electrode having the current collector with a first non-rectangular shape, an active coated portion having a second non-rectangular shape, a non-conductive insulator coated portion having a third non-rectangular shape, and a non-coated tab extending directly from the non-conductive insulator coated region, wherein the non-conductive insulator coating extends contiguously across the tab, and wherein the first non-rectangular shape of the current collector comprises nine sides, the second nonrectangular shape of the active coated region comprises eight sides, and the third non-rectangular shape of the insulator coated region comprises ten sides. 
 
     
     
       19. The method of  claim 18 ,
 wherein the insulator coated portion is disposed along a periphery of each electrode of the plurality of electrodes; and 
 wherein at least three portions along the periphery of each electrode of the plurality of electrodes are not coated with the active coating. 
 
     
     
       20. The method of  claim 19 , wherein the periphery comprises a first, second, third and fourth side of each electrode of the plurality of electrodes, the first side abutting the second side, the second side abutting the third side, and the third side abutting the fourth side.

Description:
PRIORITY 
     This application claims the benefit under 35 U.S.C. § 119(e) of U.S. Provisional Patent Application Ser. No. 62/528,700, entitled “NON-RECTANGULAR SHAPED ELECTRODES UTILIZING COMPLEX SHAPED INSULATION,” filed on Jul. 5, 2017, which is incorporated herein by reference in its entirety. 
    
    
     TECHNICAL FIELD 
     The present disclosure relates generally to battery cells, and more particularly, to non-rectangular shaped electrodes utilizing complex shaped insulation coating. 
     BACKGROUND 
     Battery cells are presently used to provide power to a wide variety of portable electronic devices, including laptop computers, tablet computers, mobile phones, personal digital assistants (PDAs), digital music players, watches, and wearable devices. A commonly used type of battery is a lithium battery, which can include a lithium-ion or a lithium-polymer battery. 
     Lithium batteries often include cells that are made of alternating layers of anode and cathode electrodes, with a separator disposed there-between. The layers may be packaged in a flexible pouch or case. Such pouches or cases may be tailored to various cell dimensions, allowing lithium batteries to be used in space-constrained portable electronic devices. The anode electrodes may be connected together using a common anode tab that is coupled to corresponding tabs disposed on each of the anode electrodes. The cathode electrodes may be similarly connected together using a common cathode tab that is coupled to corresponding tabs disposed on each of the cathode electrodes. The common anode tab and the common cathode tab may extend from their respective electrodes disposed within the pouch or case to allow the cell&#39;s energy to be transferred to an external component. The pouch or case enclosing the anode and cathode electrodes may be filled with electrolyte. 
     The common anode or cathode tabs are conventionally manufactured using a die process which often results in sharp edges or burs along the periphery of the common tabs. To prevent or reduce the risk of unwanted shorting and to increase protection, each anode and/or cathode electrode may be coated with a linear strip of an insulating material to prevent or reduce the likelihood that a common tab with a sharp edge or burr may inadvertently contact an adjacent electrode thereby causing a short that could lead to a thermal event. The insulating material, however, is conventionally applied linearly and only allows for placement of the common tabs on a single side of the electrode. 
     SUMMARY 
     The disclosed embodiments provide a non-rectangular electrode having a non-rectangular insulator coated region for placement of a common tab on various sides of the electrode. The electrode includes a current collector having a first non-rectangular shape, an active coated region having a second non-rectangular shape, an insulator coated region having a third non-rectangular shape, and a tab disposed adjacent to the insulator coated region. 
     In some embodiments, a battery cell includes a plurality of layers, an enclosure enclosing the plurality of layers, and a set of tabs extending from the pouch. The plurality of layers includes a cathode, a separator, and an anode. The anode and cathode each include a current collector having a non-rectangular shape, an active coated region having a non-rectangular shape, an insulator coated region having a non-rectangular shape, and a tab disposed adjacent to the insulator coated region. 
     In some embodiments, a method for creating a plurality of electrodes. The method includes applying an active coating on a current collector in a non-rectangular shape, applying an insulator coating in a complex shape, and creating a plurality of electrodes from the current collector. Each electrode has an active coated portion, an insulator coated portion, and a non-coated tab. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The embodiments herein may be better understood by referring to the following description in conjunction with the accompanying drawings in which like reference numerals indicate identical or functionally similar elements. Understanding that these drawings depict only exemplary embodiments of the disclosure and are not therefore to be considered to be limiting of its scope, the principles herein are described and explained with additional specificity and detail through the use of the accompanying drawings in which: 
         FIG. 1  illustrates an example of an uncut electrode sheet; 
         FIG. 2A  illustrates perspective view of an example cut electrode sheet; 
         FIG. 2B  illustrates top view of an example cut electrode sheet; 
         FIG. 3  illustrates a perspective view of an example single electrode; 
         FIG. 4  illustrates a perspective view of an uncut electrode sheet, in accordance with various aspects of the subject technology; 
         FIG. 5A  illustrates a perspective view of a cut electrode sheet, in accordance with various aspects of the subject technology; 
         FIG. 5B  illustrates a top view of a cut electrode sheet, in accordance with various aspects of the subject technology; 
         FIGS. 6A, 6B, 6C, and 6D  illustrate top views of an electrode, in accordance with various aspects of the subject technology; 
         FIG. 7A  illustrates a perspective view of a plurality of layers, in accordance with various aspects of the subject technology; 
         FIG. 7B  illustrates a top view of a plurality of layers, in accordance with various aspects of the subject technology; 
         FIG. 8  illustrates a cross-section view of an assembled battery, in accordance with various aspects of the subject technology; 
         FIG. 9  illustrates a portable electronic device, in accordance with various aspects of the subject technology; and 
         FIG. 10  illustrates an example method for creating a plurality of electrodes, in accordance with various aspects of the subject technology. 
     
    
    
     DETAILED DESCRIPTION 
     Various embodiments of the disclosure are discussed in detail below. While specific implementations are discussed, it should be understood that this is done for illustration purposes only. A person skilled in the relevant art will recognize that other components and configurations may be used without parting from the spirit and scope of the disclosure. 
     Rechargeable batteries for portable electronic devices often include cells that are made of alternating layers of anode and cathode electrodes, with a separator disposed there-between. The layers may be packaged in a flexible pouch or case. The anode electrodes may be connected together using a common anode tab that is coupled to corresponding tabs disposed on each of the anode electrodes. The cathode electrodes may be similarly connected together using a common cathode tab that is coupled to corresponding tabs disposed on each of the cathode electrodes. The common anode tab and the common cathode tab may extend from their respective electrodes disposed within the pouch or case to allow the cell&#39;s energy to be transferred to an external component. The pouch or case enclosing the anode and cathode electrodes may be filled with electrolyte. 
     Conventionally, the common anode or cathode tabs are manufactured using a die process which often results in sharp edges or burs along the periphery of the common tabs. To prevent or reduce the risk of unwanted shorting and to increase protection, each anode and/or cathode electrode may be coated with a linear strip of an insulating material to prevent or reduce the likelihood that a common tab with a sharp edge or burr may inadvertently contact an adjacent electrode thereby causing a short that could lead to a thermal event. The insulating material, however, is conventionally applied linearly and only allows for placement of the common tabs on a single side of the electrode. 
     For example, referring to  FIG. 1 , an example of an uncut electrode sheet  100  is illustrated. The uncut electrode sheet  100  may be an anode current collector  110 , such as copper, or a cathode current collector  110 , such as aluminum. A region of the current collector  110  is coated with an active coating  120  and a smaller region of the current collector is coated with an insulation coating  130 . As shown in  FIG. 1 , the insulation coating is conventionally applied linearly with a roller, longitudinally along the length of the uncut electrode sheet  100 . 
     Referring to  FIGS. 2A and 2B , to create individual electrodes  140  from the uncut electrode sheet  100 , the electrode sheet  100  is cut into a plurality of electrodes  140  thereby creating a cut electrode sheet  200 . Each electrode  140  conventionally has a region with an active coating  120 , a single strip of insulation coating  130 , and an uncoated tab  150 . 
       FIG. 3  illustrates a perspective view of an example single electrode  300  as known in the prior art. The single electrode  300  includes a region having an active coating  120  and a strip of insulation coating  130  disposed along a single edge of the electrode  300 . Because the insulation coating  130  is disposed along a single edge, placement of the tab  150  is limited to a single side or edge of the electrode  300 . Limiting tab  150  placement to a single side or edge of the electrode may require longer cable runs, causing more resistance, increases battery volume, and may decreases packaging efficiency. 
     The electrodes of the subject technology solve some or all of the foregoing problems by providing a non-rectangular shaped insulation coated region for placement of a tab on various sides of the electrode. In one aspect, by utilizing a non-rectangular shaped insulation coated region to thereby allow placement of a tab on various sides of an electrode, battery volume is decreased and packaging efficiency is improved while improving battery performance by shortening cable runs from the electrode to external components. By shortening cable runs, resistance caused by longer cable runs is eliminated. 
       FIG. 4  illustrates a perspective view of an uncut electrode sheet  400 , in accordance with various aspects of the subject technology. The uncut electrode sheet  400  may comprise an anode current collector  410 , such as a copper foil, or a cathode current collector  410 , such as an aluminum foil. A region of the current collector  410  is coated with an active coating  420  such as carbon or graphite for the anode, or a lithium compound (e.g., LiCoO 2 , LiNCoMn, LiCoAl or LiMn 2 O 4 ) for the cathode. The active coating  420  may be applied in a non-rectangular shape and in a repeating pattern. In one aspect, the non-rectangular shape of the active coating  420  may be mirrored along a centerline of the current collector  410 . 
     The current collector  410  also includes a region coated with insulation material  430 . The insulation material may be a ceramic, ceramic dielectric, composite, epoxy, oxide, polypropylene, polymer, acrylic, or any combination thereof. In some aspects, other electrical insulating materials may be used, as may be known by a person of ordinary skill in the art. In one aspect, the insulation material is configured to prevent a short that may be caused by coming into contact with an adjacent electrode or common tab, as discussed further below with reference to  FIGS. 7A and 7B . The insulation coating  430  may be applied adjacent to an edge of the active coating  420 . In one aspect, the insulation coating  430  may be applied on or over a portion of the active coating  420 . In another aspect, the insulation coating  430  may follow a similar geometry as the edge of the active coating  420 . In some aspects, the insulation coating  430  may be applied to have a width of about 1.0 mm to 5.0 mm. In some aspects, insulation coating  430  can be applied in increments of about 0.25 mm. The insulation coating  430  may be applied in a non-rectangular shape and in a repeating pattern. In one aspect, the non-rectangular shape of the insulation coating  430  may be mirrored along a centerline of the current collector  410 . 
       FIGS. 5A and 5B  illustrate views of a cut electrode sheet  500 , in accordance with various aspects of the subject technology. The uncut electrode sheet  400  may be cut into a plurality of electrodes  440  thereby forming the cut electrode sheet  500 . Each electrode of the plurality of electrodes  440  may have a similar shape. In one aspect, the shape of each electrode of the plurality of electrodes  440  may be non-rectangular. In another aspect, the shape of each electrode  440  may be based on maximizing the number of sides or edges of the electrode having an insulated coated region  430 . Each electrode  440  may be comprised of a portion of the current collector  410 , an active coated region  420 , an insulated coated region  430 , and an uncoated tab  450 . 
       FIGS. 6A, 6B, 6C, and 6D  illustrate top views of an electrode  600 , in accordance with various aspects of the subject technology. The electrode  600  may comprise a portion of the current collector  410 , an active coated region  420 , an insulated coated region  430 , and an uncoated tab  450 . The current collector  410  may have a non-rectangular shape comprising a first planar surface (e.g., top surface) and a second planar surface (e.g., bottom surface). The second planar surface may be disposed opposite the first planar surface. In one aspect, the non-rectangular shape of the current collector  410  has a shape geometry of more than four sides. For example, the non-rectangular shape of the current collector  410  may have six sides forming an “L” shape. By way of another example, the non-rectangular shape of the current collector  410  may have eight sides forming a “U” shape. In some aspects, the non-rectangular shape of the current collector  410  may have one or more curved sides and may, for example, also include circular shapes that are non-rectangular. In another aspect, if the current collector  410  includes the tab  450 , then the number of sides of the current collector  410  may increase accordingly. For example, for a current collector having an “L” shape with about six sides, including the tab  450  may increase the number of sides of the non-rectangular shape to nine sides if the tab has a rectangular or square shape. 
     The active coated region  420  of the electrode  600  may be disposed on a portion of the first planar surface of the current collector  410 . The active coated region  420  may have a non-rectangular shape. In one aspect, the non-rectangular shape of the active coated region  420  may be different from the non-rectangular shape of the current collector  410 . For example, if the current collector  410  forms an “L” shape and has six sides, the active coated region  420  may have eight sides. If the current collector  410  includes the tab  450 , the current collector may have nine sides and the active coated region  420  may have eight sides. 
     The insulator coated region  430  of the electrode  600  may be disposed on a portion of the first planar surface of the current collector  410 . The insulator coated region  430  may have a non-rectangular shape. In one aspect, the non-rectangular shape of the insulator coated region  430  may be different from the non-rectangular shape of the current collector  410  and the non-rectangular shape of the active coated region  420 . For example, if the current collector  410  forms an “L” shape and has six sides, the active coated region  420  may have eight sides, and the insulator coated region  430  may have ten sides. If the current collector  410  includes the tab  450 , the current collector may have nine sides, the active coated region  420  may have eight sides, and the insulator coated region  430  may have ten sides. 
     In one example, the portions of the current collector  410  having the active coating  420  and the insulator coating  430  may be different or separate portions of the current collector  410 . In another example, the portion of the current collector  410  having the insulator coating  430  may include a portion of the active coated region  420 . In this example, the insulator coated region  430  may be applied on or over a portion of the active coated region  420 . 
     In one aspect, the insulator coated region  430  may be disposed along a periphery of the current collector  410 . For example, referring to  FIG. 6A , the insulator coated region  430  may extend along a periphery of the current collector  410  to create an insulated coated region on a first side  430 A of the current collector  410  and a second side  430 B of the current collector  410 . By way of another example, the insulator coated region  430  may extend along the periphery of the current collector  410  to create an insulated coated region on the first side  430 A, the second side  430 B, and a third side  430 C of the current collector  410 . By way of yet another example, the insulator coated region  430  may extend along the periphery of the current collector  410  to create an insulated coated region on the first side  430 A, the second side  430 B, the third side  430 C, and a fourth side  430 D of the current collector  410 . In some aspects, the first side  430 A may abut the second side  430 B, the second side  430 B may abut the third side  430 C, and the third side  430 C may abut the fourth side  430 D. 
     The tab  450  may comprise an uncoated region of the current collector  410 . In some aspects, the tab  450  may be configured to provide an area for coupling with a common tab (as shown in  FIG. 7B ). By providing an uncoated region on the current collector  410  for coupling to a common tab, the energy of the electrode  600  may be transferred to an external component. In other aspects, the tab  450  may allow other electrodes  600  to be coupled together through welding or bonding of the respective tabs  450  of the other electrodes  600 . 
     The tab  450  may be disposed adjacent to the insulator coated regions  430 A-D to prevent an accidental or inadvertent short with an adjacent electrode or common tab, as discussed below with reference to  FIGS. 7A and 7B . Referring to  FIG. 6A , the tab  450  may be disposed adjacent to the first side of the insulator coated region  430 A. By way of another example and referring to  FIG. 6B , the tab  450  may be disposed adjacent to the second side of the insulator coated region  430 B. By way of yet another example and referring to  FIG. 6C , the tab  450  may be disposed adjacent to the third side of the insulator coated region  430 C. By way of yet another example and referring to  FIG. 6D , the tab  450  may be disposed adjacent to the fourth side of the insulator coated region  430 D. 
     In one aspect, the electrode  600  may include an active coated region and an insulator coated region disposed on the second planar surface of the current collector  410 . The active coated region may be disposed on a portion of the second planar surface and may have a non-rectangular shape. In some aspects, the non-rectangular shape of the active coated region disposed on the second planar surface may be substantially the same as the non-rectangular shape of the active coated region  420  disposed on the first planar surface of the current collector  410 . 
     The insulator coated region may be disposed on a portion of the second planar surface and may have a non-rectangular shape. In some aspects, the non-rectangular shape of the insulator coated region disposed on the second planar surface may be substantially the same as the non-rectangular shape of the insulator coated region  430  disposed on the first planar surface of the current collector  410 . 
       FIG. 7A  illustrates a perspective view of a plurality of layers  700 , in accordance with various aspects of the subject technology. The plurality of layers  700  may include a cathode electrode  600 A, a separator  710 , and an anode electrode  600 B. Each electrode  600 A,  600 B has an active coated region and an insulator coated region  430  disposed on a periphery of each electrode  600 A,  600 B. Each electrode  600 A,  600 B also has an uncoated tab  450 A,  450 B disposed adjacent to their respective insulator coated regions  430 . The separator  710  may comprise a micro-porous membrane and may include polyethylene (PP), polypropylene (PP), and/or a combination of PE and PP, such as PE/PP or PP/PE/PP. The cathode  600 A, separator  710 , and electrode  600 B may be arranged in a stacked configuration. 
     Referring to  FIG. 7B , a top view of the plurality of layers  700  is illustrated, in accordance with various aspects of the subject technology. The separator  710  may have a non-rectangular shape that may be substantially similar to the non-rectangular shape of the electrodes  600 A,  600 B. The separator  710  may be larger in area than either of the electrodes  600 A,  600 B to prevent inadvertent contact between the cathode  600 A and the anode  600 B. In one aspect, the cathode  600 A may be smaller in area and may be subsumed by the anode  600 B. 
     In some aspects, a location of the tab  450 A for the cathode  600 A may be at a different location than a location of the tab  450 B for the anode  600 B. For example, the location of the tabs  450 A,  450 B may be along any edge or side having the insulator coating region  430 , including the first side  430 A, second side  430 B, third side  430 C or fourth side  430 D, as shown in  FIG. 6A . 
     The tab  450 A for the cathode  600 A may be coupled to a cathode common tab  720 A. The tab  450 B for the anode  600 B may be coupled to an anode common tab  720 B. The cathode common tab  720 A and the anode common tab  720 B may extend from their respective electrodes  600 A,  600 B to provide an external electrical connection, as discussed below with reference to  FIG. 8 . The common tabs  720 A,  720 B are conventionally manufactured using a die process. As such, one or more edges of the common tabs  720 A,  720 B may have a burr or sharp edge that may exceed acceptable tolerances. In such circumstances, a bur or sharp edge of a common tab  720 A,  720 B may penetrate the separator  710  and come into inadvertent contact with an adjacent electrode. If the adjacent electrode is without an insulator coated region, an electrical short may occur leading to a thermal event or failure of the battery. For example, referring to  FIG. 7B , an edge  722  of the common tab  720 A of the cathode  600 A may overlap with a portion of the anode  600 B. If the edge  722  contains a burr that exceeds acceptable tolerances, insulator coated region  430 B prevents a short from occurring. 
     Referring to  FIG. 8 , a cross-section view of an assembled battery  800  is illustrated, in accordance with various aspects of the subject technology. The assembled battery  800  includes a battery cell  810 , a battery management unit  820 , and battery terminals  830 . The battery management unit  820  is configured to manage recharging of the battery  800 . The terminals  830  are configured to engage with corresponding connectors on a portable electronic device to provide power to components of the portable electronic device. 
     The battery cell  810  includes a plurality of layers comprising the cathode with an active coating  600 A, the separator  710 , and the anode with an active coating  600 B. The plurality of layers  810  may be wound to form a jelly roll structure or can be stacked to form a stacked-cell structure. The plurality of layers  810  are enclosed within a pouch or casing  840  and immersed in an electrolyte  850 , which for example, can be a LiPF6-based electrolyte that can include Ethylene Carbonate (EC), Polypropylene Carbonate (PC), Ethyl Methyl Carbonate (EMC) or DiMethyl Carbonate (DMC). The electrolyte can also include additives such as Vinyl carbonate (VC) or Polyethylene Soltone (PS). The electrolyte can additionally be in the form of a solution or a gel. 
     The anode layers  600 B of the plurality of layers  810  are coupled to a first conductive tab (shown in  FIG. 7B  as reference numeral  720 B). In one aspect, the first conductive tab may be coupled to the anode layers  600 B via an uncoated tab (shown in  FIG. 7B  as reference numeral  450 B). The cathode layers  600 A of the plurality of layers  810  are coupled to a second conductive tab  720 A. In one aspect, the second conductive tab  720 A may be coupled to the cathode layers  600 A via the uncoated tab  450 A. The first common tab and the second common tab  720 B may extend from the battery cell  810  for electrical connection to other battery cells, the battery management unit  820 , or other components as desired. 
     Referring to  FIG. 9 , a portable electronic device  900  is illustrated, in accordance with various aspects of the subject technology. The above-described rechargeable battery  800  can generally be used in any type of electronic device. For example,  FIG. 9  illustrates a portable electronic device  900  which includes a processor  902 , a memory  904  and a display  908 , which are all powered by a battery  800 . Portable electronic device  900  may correspond to a laptop computer, tablet computer, mobile phone, personal digital assistant (PDA), digital music player, watch, and wearable device, and/or other type of battery-powered electronic device. Battery  800  may correspond to a battery pack that includes one or more battery cells. Each battery cell may include a set of layers sealed in a pouch or case, including a cathode with an active coating, a separator, an anode with an active coating, and may utilize electrodes having a complex shaped insulation coating to prevent accidental or inadvertent electrical shorts that may be caused by burrs or sharp edges on a common tab coupled to the cathode or anode. 
       FIG. 10  illustrates an example method  1000  for creating a plurality of electrodes, in accordance with various aspects of the subject technology. It should be understood that, for any process discussed herein, there can be additional, fewer, or alternative steps performed in similar or alternative orders, or in parallel, within the scope of the various embodiments unless otherwise stated. 
     At operation  1010 , an active coating is applied on a current collector in a non-rectangular shape. As discussed above, the non-rectangular shape may include any shape having more than four sides. Alternatively, the non-rectangular shape may include a shape having curvature or other non-linear shapes. 
     At operation  1020 , an insulator coating is applied on the current collector in a complex shape. The insulator coating may be disposed adjacent to the active coating. As discussed above, the complex shape may be a non-rectangular shape that is different from the non-rectangular shape of the active coating. 
     At operation  1030 , a plurality of electrodes is created from the current collector through a cutting, stamping, die, or similar process. Each electrode of the plurality of electrodes has an active coated portion, an insulator coated portion, and a non-coated tab. In one aspect, the insulator coated portion may be disposed along a periphery of each electrode of the plurality of electrodes. The periphery may include a first, second, third and fourth side of each electrode of the plurality of electrodes. The first side may abut the second side, the second side may abut the third side, and the third side may abut the fourth side. 
     The tab may be disposed on the first side of each electrode of the plurality of electrodes. Alternatively, the tab may be disposed on the second side of each electrode of the plurality of electrodes. As yet another example, the tab may be disposed on the third side of each electrode of the plurality of electrodes. As yet another example, the tab may be disposed on the fourth side of each electrode of the plurality of electrodes. 
     Although a variety of examples and other information was used to explain aspects within the scope of the appended claims, no limitation of the claims should be implied based on particular features or arrangements in such examples, as one of ordinary skill would be able to use these examples to derive a wide variety of implementations. Further and although some subject matter may have been described in language specific to examples of structural features and/or method steps, it is to be understood that the subject matter defined in the appended claims is not necessarily limited to these described features or acts. For example, such functionality can be distributed differently or performed in components other than those identified herein. Rather, the described features and steps are disclosed as examples of components of systems and methods within the scope of the appended claims.

Metadata:
Filing Date: 20171206
Publication Date: 20220802
Grant Date: 20220802
Priority Date: 20170705
Inventors: LONDARENKO, YURIY Y.
AMIRUDDIN, SHABAB
Assignee: APPLE INC
CPC Classifications: [{"code": "H01M50/534", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01M50/533", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01M4/70", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01M4/0404", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01M4/0404", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01M50/46", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01M10/052", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01M4/70", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01M50/46", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01M4/13", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01M2004/021", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01M50/533", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01M50/534", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01M4/13", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01M4/13", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01M10/052", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01M50/46", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01M4/70", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01M2004/021", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01M4/0404", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01M50/531", "inventive": true, "first": false, "tree": "[]"}]
Family ID: 64904220