PATENT DOCUMENT

Publication Number: US-11145925-B2
Application Number: US-201816211433-A
Country: US
Kind Code: B2

Title: Cylindrical battery cell with overmolded glass feedthrough

Abstract:
The disclosed technology relates to an electrical feedthrough for a cylindrical battery cell. The electrical feedthrough may include an annular channel having an outer sidewall, an inner sidewall, and a base; an insulator formed of glass having an overmold portion; and a pin extending through the insulator and configured to form an external battery terminal. The insulator is bonded to the inner sidewall of the annular channel and a portion of the base of the annular channel. The overmold portion prevents electrical contact between a set of electrodes and the electrode feedthrough.

Claims:
What is claimed is: 
     
       1. A battery cell, comprising:
 a wound set of layers comprising a cathode layer, an anode layer, and a separator layer disposed between the cathode layer and the anode layer; 
 a cylindrical enclosure enclosing the set of layers, the enclosure comprising an opening for receiving a feedthrough, the feedthrough comprising:
 an annular channel comprising an outer sidewall, an inner sidewall, and a base; 
 an insulator formed of glass, the insulator bonded to the inner sidewall of the annular channel and a portion of the base of the annular channel, the insulator further comprising an overmold portion that extends between the base of the annular channel and the set of layers, the overmold portion configured to prevent electrical contact between the set of layers and the annular channel; and 
 a pin extending through the insulator, the pin electrically coupled to the set of layers to form an external battery terminal. 
 
 
     
     
       2. The battery cell of  claim 1 , wherein the outer sidewall of the annular channel is welded to the enclosure along a periphery of the opening. 
     
     
       3. The battery cell of  claim 1 , further comprising a tab extending from the set of layers, wherein the pin is welded to the tab proximal to the opening. 
     
     
       4. The battery cell of  claim 3 , wherein the tab comprises a fold proximal to the annular channel, and wherein the insulator prevents electrical contact between the fold of the tab and the annular channel. 
     
     
       5. The battery cell of  claim 4 , wherein the overmold portion of the insulator has a diameter that extends radially beyond the fold of the tab. 
     
     
       6. The battery cell of  claim 1 , wherein the cylindrical enclosure further comprises a second opening disposed opposite the first opening, the second opening configured to receive a second feedthrough, the second feedthrough comprising:
 a second annular channel comprising an outer sidewall, an inner sidewall, and a base; 
 a second insulator formed of glass, the second insulator bonded to the inner sidewall of the second annular channel and a portion of the base of the second annular channel, the second insulator further comprising an overmold portion that extends between the base of the second annular channel and the set of layers, the overmold portion configured to prevent electrical contact between the set of layers and the second annular channel; and 
 a second pin extending through the second insulator, the second pin electrically coupled to the set of layers to form a second external battery terminal. 
 
     
     
       7. The battery cell of  claim 6 , wherein the outer sidewall of the second annular channel is welded to the enclosure along a periphery of the second opening. 
     
     
       8. A battery feedthrough, comprising:
 an annular channel comprising an outer sidewall, an inner sidewall, and a base; 
 an insulator formed of glass, the insulator bonded to the inner sidewall of the annular channel and a portion of the base of the annular channel, the insulator further comprising an overmold portion that extends from the base of the annular channel; and 
 a pin extending through the insulator, the pin configured to form an external battery terminal. 
 
     
     
       9. The battery feedthrough of  claim 8 , wherein the outer sidewall of the annular channel is configured to be welded to a battery cell enclosure along a periphery of the enclosure. 
     
     
       10. The battery feedthrough of  claim 8 , wherein a material of the annular channel comprises stainless steel. 
     
     
       11. The battery feedthrough of  claim 8 , wherein a material of the pin comprises molybdenum. 
     
     
       12. A method for manufacturing a battery cell, the method comprising:
 inserting a set of layers within a cylindrical enclosure through an opening, the set of layers comprising a cathode layer, an anode layer, and a separator layer disposed between the cathode layer and the anode layer; 
 welding a tab extending from the set of layers to a pin, the pin electrically coupled to the set of layers to form an external battery terminal; 
 folding the tab within the cylindrical enclosure; 
 disposing a feedthrough within the opening of the cylindrical enclosure, the feedthrough comprising:
 an annular channel comprising an outer sidewall, an inner sidewall, and a base; 
 an insulator formed of glass, the insulator bonded to the inner sidewall of the annular channel and a portion of the base of the annular channel, the insulator further comprising an overmold portion that extends from the base of the annular channel, the overmold portion configured to prevent electrical contact between the set of layers and the annular channel; and 
 the pin, the pin extending through the insulator. 
 
 
     
     
       13. The method of  claim 12 , further comprising welding the outer sidewall of the annular channel to the cylindrical enclosure along a periphery of the opening. 
     
     
       14. The method of  claim 12 , further comprising filling the cylindrical enclosure with electrolyte. 
     
     
       15. The method of  claim 12 , wherein the overmold portion of the insulator has a diameter that extends radially beyond the folded tab. 
     
     
       16. The method of  claim 12 , further comprising disposing a second feedthrough within a second opening of the cylindrical enclosure, the second feedthrough comprising:
 a second annular channel comprising an outer sidewall, an inner sidewall, and a base; 
 a second insulator formed of glass, the second insulator bonded to the inner sidewall of the second annular channel and a portion of the base of the second annular channel, the second insulator further comprising an overmold portion that extends from the base of the second annular channel, the overmold portion configured to prevent electrical contact between the set of layers and the second annular channel; and 
 a second pin extending through the second insulator, the second pin electrically coupled to the set of layers to form a second external battery terminal. 
 
     
     
       17. The method of  claim 16 , further comprising welding the outer sidewall of the second annular channel to the cylindrical enclosure along a periphery of the second opening. 
     
     
       18. The method of  claim 12 , wherein a material of the annular channel comprises stainless steel. 
     
     
       19. The method of  claim 12 , wherein a material of the cylindrical enclosure comprises stainless steel. 
     
     
       20. The method of  claim 12 , wherein a material of the pin comprises molybdenum.

Description:
PRIORITY 
     This application claims the benefit under 35 U.S.C. § 119(e) of U.S. Provisional Patent Application Ser. No. 62/727,778, entitled “CYLINDRICAL BATTERY CELL WITH OVERMOLDED GLASS FEEDTHROUGH,” filed on Sep. 6, 2018, which is incorporated herein by reference in its entirety. 
    
    
     TECHNICAL FIELD 
     The present disclosure relates generally to cylindrical battery cells, and more particularly, to a cylindrical battery cell with an overmolded glass feedthrough. 
     BACKGROUND 
     Battery cells are 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 an cylindrical enclosure. Anode electrodes of the cell may be electrically coupled to a wall of the enclosure where the enclosure is itself, made of a conductive material. The cathode electrodes, however, may require an electrical feedthrough to enable an electrical connection, through the enclosure, to the cathode electrodes. In addition, electrical feedthroughs must insulate the electrical connection to the cathode electrodes from the enclosure to prevent shorting of the battery cell. The enclosure enclosing the electrodes may be filled with electrolyte thereby requiring the electrical feedthrough to also provide a hermetically seal to prevent unwanted leakage or failure. 
     Conventional feedthroughs for cylindrical battery cells may utilize a crimping operation to attach the feedthrough to the enclosure. Such crimping operations, however, may require additional space on the enclosure to accommodate the crimp and to ensure a proper seal, thereby reducing packaging efficiency. 
     SUMMARY 
     The disclosed embodiments provide for a battery cell that utilizes an overmolded glass feedthrough to prevent electrical contact or shorting of electrodes to the feedthrough. The battery cell includes a wound set of layers that include a cathode layer, an anode layer, and a separator layer disposed between the cathode layer and the anode layer. The set of layers are enclosed within a cylindrical enclosure having an opening for receiving a feedthrough. The feedthrough includes an annular channel having an outer sidewall, an inner sidewall, and a base; an insulator formed of glass; and a pin extending through the insulator. The insulator is bonded to the inner sidewall of the annular channel and a portion of the base of the annular channel. The insulator also includes an overmold portion that extends between the base of the annular channel and the set of layers. The overmold portion is configured to prevent electrical contact between the set of layers and the annular channel. The pin is electrically coupled to the set of layers to form an external battery terminal. 
     In some embodiments, a battery feedthrough includes an annular channel, an insulator, and a pin. The annular channel may include an outer sidewall, an inner sidewall, and a base. The insulator may be formed of glass, and bonded to the inner sidewall of the annular channel and a portion of the base of the annular channel. The insulator further includes an overmold portion that extends from the base of the annular channel. The pin is configured to form an external battery terminal. 
     In some embodiments, a method for manufacturing a battery cell is disclosed. The method includes inserting a set of layers within a cylindrical enclosure through an opening. The set of layers include a cathode layer, an anode layer, and a separator layer disposed between the cathode layer and the anode layer. The method also includes welding a tab extending from the set of layers to a pin, the pin electrically coupled to the set of layers to form an external battery terminal. The method further includes folding the tab within the cylindrical enclosure and disposing a feedthrough within the opening of the cylindrical enclosure. The feedthrough includes an annular channel having an outer sidewall, an inner sidewall, and a base. The feedthrough also includes an insulator formed of glass that is bonded to the inner sidewall of the annular channel and a portion of the base of the annular channel. The insulator includes an overmold portion that extends from the base of the annular channel. The overmold portion is configured to prevent electrical contact between the set of layers and the annular channel. The feedthrough also includes the pin extending through the insulator. 
    
    
     
       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. 1A  illustrates a perspective view of a conventional cylindrical battery cell; 
         FIG. 1B  illustrates a cross-section view of a conventional cylindrical battery cell; 
         FIG. 2  illustrates a cross-section view of a cylindrical battery cell with an overmolded glass feedthrough, in accordance with various aspects of the subject technology; 
         FIG. 3  illustrates a detailed cross-section view of a cylindrical battery cell with an overmolded glass feedthrough, in accordance with various aspects of the subject technology; 
         FIG. 4  illustrates a cross-section view of an assembled battery cell, in accordance with various aspects of the subject technology; 
         FIG. 5  illustrates a portable electronic device, in accordance with various aspects of the subject technology; and 
         FIG. 6  illustrates an example method for manufacturing a battery cell, 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 an enclosure and may utilize an electrical feedthrough to make an electrical connection to cathode electrodes through the enclosure. The enclosure enclosing the electrodes may be filled with electrolyte thereby requiring the feedthrough to hermetically seal the enclosure to prevent unwanted leakage or failure. In addition, electrical feedthroughs must insulate the electrical connection from the enclosure to prevent shorting of the battery cell. 
     Conventional feedthroughs for cylindrical battery cells may utilize a crimping operation to attach the feedthrough to the enclosure. Such crimping operations, however, require additional space on the enclosure to accommodate the crimp and to ensure a proper seal, thereby reducing packaging efficiency. Accordingly, there is a need for certain embodiments of a compact and robust feedthrough for use in small or thin cylindrical battery cells that improves packaging efficiency and increases energy capacity. 
     The disclosed technology addresses the foregoing limitations of conventional feedthroughs for cylindrical battery cells by utilizing a glass feedthrough that utilizes an overmold to insulate the feedthrough from the electrodes, thereby improving packaging efficiency and increasing energy capacity by eliminating the need for a crimping operation and associated components. 
       FIGS. 1A and 1B  illustrate views of a conventional cylindrical battery cell  100 . The conventional cylindrical battery cell  100  utilizes a crimping operation to create a crimp  110  at a feedthrough. The crimp  110  requires use of an insert  120  that creates a mechanical stop for the crimping operation, and when crimped, creates a seal between an enclosure of the battery cell  100  and the feedthrough. As shown in  FIG. 1B , the insert  120  and other components associated with a successful crimping operation results in a distance H 1  between a set of layers or jelly roll, and an end of the battery cell  100 . Specifically, in order to adequately crimp sidewalls of the enclosure to the insert  120 , there must be sufficient area surrounding the crimp  110  to allow a crimping operation to be performed. 
       FIG. 2  illustrates a cross-section view of a cylindrical battery cell  200  with an overmolded glass feedthrough, in accordance with various aspects of the subject technology. The battery cell  200  comprises a cylindrical enclosure  210  having a first opening  270 , a wound set of layers  250  enclosed within the cylindrical enclosure  210 , and a feedthrough  220 . The enclosure  210  may be formed of a rigid material, such as a metal alloy which may, for example, include stainless steel, aluminum, aluminum alloy, or other sufficiently rigid materials as would be known by a person of ordinary skill in the art. The enclosure  210  may have a non-corrosive coating line the interior of the enclosure  210  and is configured to enclose and protect one or more sets of electrodes or layers disposed within the enclosure. The enclosure  210  may have a cylindrical, cuboid, prism, conical, or pyramid shape. In one aspect, the enclosure  210  may be drawn from tube stock to form a cylinder having the first opening  270  and a second opening  280 . In other aspects, the enclosure  210  may have a closed end opposite the first opening  270 . The first opening  270  and/or the second opening  280  may each be configured to receive the feedthrough  220 . 
     The wound set of layers  250  may comprise at least one cathode layer with an active coating, a separator, and at least one anode layer with an active coating, as discussed below with reference to  FIG. 4 . A tab (as shown in  FIG. 3 ) may extend from the anode and/or cathode layers, as discussed further below. 
     The feedthrough  220  may comprise an annular channel  230 , an insulator  240 , and a pin  260 . The feedthrough  220  is configured to seal the set of layers  250  within the enclosure  210  and to provide an electrical connection to the anode or cathode layer of the set of layers  250  via the pin  260 . The feedthrough  220  may be disposed within the first opening  270  and bonded, glued, welded, or coupled, to the enclosure  210 . As shown in  FIG. 2 , the feedthrough  220  eliminates the need for a crimping operation by utilizing a bonding, gluing, welding, or coupling operation, and utilizes an overmolded insulator  240  to prevent inadvertent electrical contact between the annular channel  230  and the set of layers  250 . As a result, a distance H 2  between the set of layers  250  (e.g., jelly roll) and an end of the battery cell  200  is reduced when compared to the conventional battery cell  100  of  FIG. 1B , thereby improving packaging efficiency and increasing energy capacity by eliminating the need for a crimping operation and associated components. 
       FIG. 3  illustrates a detailed cross-section view of the cylindrical battery cell  200  with the overmolded glass feedthrough  220 , in accordance with various aspects of the subject technology. The annular channel  230  of the feedthrough  220  comprises an outer sidewall, an inner sidewall, and a base. The outer sidewall of the annular channel  230  contacts a corresponding sidewall of the enclosure  210 , and after a bonding, gluing, welding, or coupling operation, creates a hermetic seal between the feedthrough  220  and the enclosure  210 . For example, the annular channel  230  may be welded to the opening  270  of the enclosure  210  along a periphery by welding the outer sidewall of the annular channel  230  to the sidewall of the enclosure  210 . The annular channel  230  may be made of a rigid material, and may further be made of a material that is adequate for welding to the enclosure  210 . For example, if the enclosure  210  is formed of a stainless steel material, the annular channel  230  may also be formed of a stainless steel material to enable welding of the annular channel  230  and enclosure  210 . 
     The insulator  240  is formed of an electrically insulating material, such as glass, and includes an overmold portion  242  to prevent electrical contact between the cathode  254  or anode  256  of the set of layers, and the annular channel  230 . The insulator  240  may be bonded to the inner sidewall of the annular channel  230  and a portion of the base of the annular channel  230 . The insulator  240  is also bonded to the pin  260  and surrounds the pin  260 . The overmold portion  242  of the insulator  240  extends between the base of the annular channel  230  and the separator  252  of the set of layers. As discussed above, the overmold portion  242  prevents electrical contact between the set of layers and the annular channel  230 . 
     The pin  260  extends through the insulator  240  and is electrically coupled to the cathode  254  or anode  256  of the set of layers to form an external battery terminal. The pin may comprise a metal or alloy, or material that is capable of conducting electricity, such as molybdenum. In one aspect, the pin  260  may be spot welded to a tab  258  extending from the cathode  254  or anode  256  of the set of layers. The tab  258  may extend from the opening  270  to facilitate a spot welding operation to the pin  260 . When coupled to the tab  258  extending from the set of layers, electrical energy from the cathode  254  or anode  256 , for example, passes through the tab  258  and to the pin  260 , to thereby provide an external terminal for the battery cell  200 . After welding, the tab  258  may be configured to be stowed or folded within the enclosure  210 , proximal to the feedthrough  220 , and more specifically, proximal to the annular channel  230 . The overmold portion  242  of the insulator  240  is further configured to prevent electrical contact between the fold of the tab  258  and the annular channel  230 . For example, by extending a diameter of the overmold portion  242  to extend radially beyond the fold of the tab  258 , electrical contact between the fold of the tab  258  and the annular channel  230  is prevented. 
     In some aspects, the battery cell  200  may further comprise a second feedthrough disposed at the second opening  280  (as shown in  FIG. 2 ). The second opening  280  may be disposed opposite the first opening  270 . The second feedthrough may comprise the same components as the feedthrough  220 , which may include a second annular channel (similar to annular channel  230 ), a second insulator (similar to insulator  240 ), and a second pin (similar to pin  260 ). The second feedthrough is configured to electrically couple the cathode  254  or anode  256  of the set of layers to form a second external battery terminal. 
       FIG. 4  illustrates a cross-section view of an assembled battery  400 , in accordance with various aspects of the subject technology. The assembled battery  400  includes the battery cell  200 , enclosure  210 , feedthrough  220 , a battery management unit  410 , and battery terminals  420 . The battery management unit  410  is configured to manage recharging of the battery cell  200 . The terminals  420  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  200  includes a plurality of layers  250  comprising a cathode with an active coating  254 , a separator  252 , and an anode with an active coating  256 . For example, the cathode  254  may be an aluminum foil coated with a lithium compound (e.g., LiCoO 2 , LiNCoMn, LiCoAl or LiMn 2 O 4 ) and the anode  256  may be a copper foil coated with carbon or graphite. The separator  252  may include polyethylene (PE), polypropylene (PP), and/or a combination of PE and PP, such as PE/PP or PP/PE/PP. The separator  252  comprises a micro-porous membrane that also provides a “thermal shut down” mechanism. If the battery cell reaches the melting point of these materials, the pores shut down which prevents ion flow through the membrane. 
     The plurality of layers  250  may be wound to form a jelly roll structure or can be stacked to form a stacked-cell structure. The plurality of layers  250  are enclosed within enclosure  210  and immersed in an electrolyte  430 , 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  256  of the plurality of layers  250  may be coupled to the enclosure  210  or may be coupled to a second feedthrough via a second tab (not shown) extending from the anode layers  256 . The cathode layers  254  of the plurality of layers  250  may be coupled to a first tab  258 , which may include intermediate tabs  440  extending from each cathode layer  254 . The first tab  258  and the second tab extend from the plurality of layers  250  for electrical connection to other battery cells, the battery management unit  410 , or other components as desired. 
       FIG. 5  illustrates a portable electronic device  500 , in accordance with various aspects of the subject technology. The above-described rechargeable battery  200  can generally be used in any type of electronic device. For example,  FIG. 5  illustrates a portable electronic device  500  which includes a processor  502 , a memory  504  and a display  506 , which are all powered by the battery  200 . Portable electronic device  500  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  200  may correspond to a battery pack that includes one or more battery cells. Each battery cell may include a set of layers sealed in an enclosure, including a cathode with an active coating, a separator, an anode with an active coating, and utilize an electrical feedthrough that maximizes packaging efficiency and increases reliability by preventing accidental or inadvertent electrical shortage through implementation of a feedthrough  220  having an overmolded insulator  240 , as described above. 
       FIG. 6  illustrates an example method  600  for manufacturing a battery cell, 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  610 , a set of layers are inserted within a cylindrical enclosure through an opening in the enclosure. The set of layers comprise a cathode layer, an anode layer, and a separator layer disposed between the cathode layer and the anode layer. At operation  620 , a tab extending from the set of layers is welded to a pin of a feedthrough. The pin is electrically coupled to the set of layers to form an external battery terminal. At operation  630 , the tab is folded within the cylindrical enclosure. At operation  640 , a feedthrough is disposed within the opening of the cylindrical enclosure. As described above, the feedthrough comprises an annular channel having an outer sidewall, an inner sidewall, and a base. The feedthrough also comprises an insulator formed of glass, the insulator bonded to the inner sidewall of the annular channel and a portion of the base of the annular channel. The insulator further comprises an overmold portion that extends from the base of the annular channel to prevent electrical contact between the set of layers and the annular channel, as well as prevent electrical contact between the tab and the annular channel. The feedthrough also comprises the pin, where the pin extends through the insulator. 
     At operation  650 , the feedthrough is welded to the cylindrical enclosure by welding the outer sidewall of the annular channel to the cylindrical enclosure along a periphery of the opening. At operation  660 , the cylindrical enclosure is filled with electrolyte. 
     The method  600  may further include disposing a second feedthrough within a second opening of the cylindrical enclosure. The second feedthrough may include a second annular channel comprising an outer sidewall, an inner sidewall, and a base. The second feedthrough may also comprise a second insulator formed of glass, the second insulator bonded to the inner sidewall of the second annular channel and a portion of the base of the second annular channel. The second insulator also comprises an overmold portion that extends from the base of the second annular channel to prevent electrical contact between the set of layers and the second annular channel, as well as prevent electrical contact between a second tab extending from the set of layers and the second annular channel. The second feedthrough also comprises a second pin extending through the second insulator, the second pin electrically coupled to the set of layers to form a second external battery terminal. In one aspect, the second pin may be coupled to the second tab via a welding operation, as discussed above with respect to operation  620 . 
     The method  600  may further include welding the outer sidewall of the second annular channel to the cylindrical enclosure along a periphery of the second opening to thereby create a hermetic seal at the second opening of the cylindrical enclosure. 
     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: 20181206
Publication Date: 20211012
Grant Date: 20211012
Priority Date: 20180906
Inventors: SHIU, BRIAN K.
PASMA, CHRISTOPHER R.
CHEUNG, GERALD K.
BALARAM, HARAN
LIU, JUNHUA
Assignee: APPLE INC
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Family ID: 69719716