PATENT DOCUMENT

Publication Number: US-8709645-B2
Application Number: US-201113175292-A
Country: US
Kind Code: B2

Title: Battery pouch sheet edge insulation

Abstract:
A multi layer laminate sheet suitable to form a battery pouch is described. The laminate sheet includes a core metal layer, a sealant layer, and an insulating layer. The sealant layer is bonded to one surface of the core metal layer, and the insulating layer is bonded to the other surface of the core metal layer. The insulating layer has a width that is greater than the width of the core metal layer, such that the insulating layer extends past two edges of the core metal layer. When the pouch is formed by folding the laminate sheet, the insulating layer protects the edges of the core metal layer of the laminate sheet from being exposed around the edges or sides of the pouch. Other embodiments are also described and claimed.

Claims:
What is claimed is: 
     
       1. A multi-layer sheet suitable to form a battery pouch, comprising:
 a core metal layer having a first surface and a second surface that is opposite the first surface; 
 a sealant layer attached to the first surface of the core metal layer, wherein the multi-layer sheet has a fold therein and the sealant layer is continuous across the fold; and 
 an insulating layer attached to the second surface of the core metal layer and having a width that is greater than a width of the core metal layer such that the insulating layer extends past a left edge and a right edge of the core metal layer. 
 
     
     
       2. The multi-layer sheet of  claim 1 , wherein the core metal layer is aluminum. 
     
     
       3. The multi-layer sheet of  claim 1 , wherein the sealant layer is cast polypropylene. 
     
     
       4. The multi-layer sheet of  claim 1 , wherein the insulating layer is nylon. 
     
     
       5. The multi-layer sheet of  claim 1 , wherein a first section and a second section of the sheet are folded against each other to enclose a cavity in which an electrode assembly can be housed. 
     
     
       6. The multi-layer sheet of  claim 5 , wherein the first section and the second section are folded such that the sealant layer defines an interior of the cavity to form a pouch, and the insulating layer covers an exterior of the pouch. 
     
     
       7. The multi-layer sheet of  claim 5 , wherein the sealant layer in the first section is thermally bonded to the sealant layer in the second section to enclose the cavity in which the electrode assembly is contained. 
     
     
       8. The multi-layer sheet of  claim 7 , wherein the insulating layer in the first section and the insulating layer in the second section provide electrical insulation for the core metal layer by shielding the left and right edges of the core metal layer. 
     
     
       9. The multi-layer sheet of  claim 1 , wherein the sealant layer has a thickness in the range of 30 to 150 microns. 
     
     
       10. A battery, comprising:
 an electrode assembly; and 
 a pouch formed by first and second laminated sheet sections each of which includes a sealant layer that forms an interior lining of the pouch and an inner metal layer interposed between the sealant layer and an outer insulating layer, wherein the sealant layer in the first laminated sheet section is heat sealed in direct contact with the sealant layer in the second laminated sheet section to seal the pouch, wherein the outer insulating layer of each of the first and second laminated sheet sections forms an exterior lining of the pouch and extends beyond a left edge and a right edge of the inner metal layer to protect the left and right edges of the inner metal layer. 
 
     
     
       11. The battery of  claim 10 , wherein the electrode assembly includes a positive electrode plate and a positive electrode tab attached to the positive electrode plate, a negative electrode plate and a negative electrode tab attached to the negative electrode plate, and a separator positioned between the positive electrode plate and the negative electrode plate. 
     
     
       12. The battery of  claim 10 , wherein the outer insulating layer of the laminate sheet sections is nylon. 
     
     
       13. The battery of  claim 10 , wherein a peripheral portion of the outer insulating layer, which extends beyond of the inner metal layer, is folded over the left edge of the inner metal layer. 
     
     
       14. The battery of  claim 10 , wherein the outer insulating layer extends past each of the left and right edges of the inner metal layer by approximately 0.1 to 0.5 millimeter. 
     
     
       15. The battery of  claim 10 , wherein the sealant layer directly contacts the electrode assembly. 
     
     
       16. A battery pouch comprising:
 a multi-layer sheet having a metal layer interposed between a sealant layer and an insulating layer, the sealant layer being bonded to seal the pouch, wherein the insulating layer has a width that is greater than a width of the metal layer so that a peripheral portion of the insulating layer extends beyond an edge of the metal layer and has been folded inward to protect the edge of the metal layer from being exposed outside of the pouch when the pouch has been sealed, wherein the multi-layer sheet has a fold therein and the sealant layer is continuous across the fold. 
 
     
     
       17. The battery pouch of  claim 16  wherein the insulating layer extends beyond the edge of the metal layer by between 0.1 to 0.5 mm. 
     
     
       18. The battery pouch of  claim 16  wherein a cavity is formed in the multi-layer sheet in which a battery electrode assembly can fit, and a top section of the multi-layer sheet has been folded over a bottom section of the multi-layer sheet to cover the cavity. 
     
     
       19. The battery pouch of  claim 17  wherein a cavity is formed in the multi-layer sheet in which a battery electrode assembly can fit, and a top section of the multi-layer sheet has been folded over a bottom section of the multi-layer sheet to cover the cavity. 
     
     
       20. The battery pouch of  claim 18  wherein the cavity is sealed by bonding the sealant layer in the top section to the sealant layer in the bottom section.

Description:
An embodiment of the invention relates to a pouch type lithium polymer battery. Other embodiments are also described. 
     BACKGROUND 
     Recently, compact and light portable electronic devices, such as smart phones, notebook and tablet computers, and media players, have been actively developed and produced. Batteries are commonly used as an internal power source for such portable devices to enable the device to operate when external power sources are not available. Batteries may employ any of a number of electrochemical technologies and may be manufactured in a variety of form factors. For portable devices, interest in pouch type lithium ion polymer batteries (also referred to as lithium polymer batteries has increased because of low manufacturing costs, light weight, and easy modification in shape. 
     A pouch type lithium polymer battery is constructed by mounting an electrode assembly in a pouch type case that is made of a multi-layer laminate sheet. In conventional pouch type batteries, the multi-layer laminate sheet has a core layer that is a metallic foil. The metallic foil is substantially moisture and oxygen impervious, to prevent undesirable reactions from moisture or oxygen interacting with an electrolyte inside the case. When the case is sealed, the metal foil is exposed around the edges of the case and thus needs to be insulated to prevent corrosion of the pouch material, which may occur if the metallic foil is grounded or electrically biased as a result of unintended contact with other metal parts in the portable device. Typically, to insulate the metallic foil, the sealed edges of the case are manually folded against the sides of the case, and tape is then placed over the sealed edges to insulate the metallic foil and secure the edges against the sides of the case. This manual process of insulating the metallic foil can be time consuming and thus expensive. Furthermore, folding the sealed edges in this manner and applying tape over them increases the overall size of the battery. This may limit the size of the electrode assembly that can be placed inside the case; alternatively, it may reduce valuable space within the portable electronic device in which the battery is installed. 
     SUMMARY 
     A battery pouch sheet that inherently insulates an edge of a core metal layer of the sheet is described. The multi-layer laminate sheet includes a core layer, a sealant layer, and an insulating layer. The core layer has two surfaces. One surface of the core layer is attached to the sealant layer, and the other surface is attached to the insulating layer. The insulating layer is wider than the core layer. 
     In one embodiment, when the sheet is folded and heat sealed to form a pouch that encloses a battery electrode assembly, the sealant layer forms the interior lining of the pouch, and the insulating layer forms the exterior lining of the pouch. Because the insulating layer is wider than the core layer, e.g., similar to an overhang, the peripheral sections of the insulating layer protect the edges of the core layer from being exposed around the edges or a side of the pouch. This inherently insulates the core layer, without the need to fold and tape the peripheral sections of the insulating layer to the side of the pouch. 
     The above summary does not include an exhaustive list of all aspects of the present invention. It is contemplated that the invention includes all systems and methods that can be practiced from all suitable combinations of the various aspects summarized above, as well as those disclosed in the Detailed Description below and particularly pointed out in the claims filed with the application. Such combinations have particular advantages not specifically recited in the above summary. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Embodiments of the invention will now be described with reference to the drawings summarized below. The embodiments of the invention are illustrated by way of example and not by way of limitation in the figures of the accompanying drawings in which like references indicate similar elements. It should be noted that references to “an” or “one” embodiment of the invention in this disclosure are not necessarily to the same embodiment, and they mean at least one. 
         FIG. 1  is a perspective view of a multi-layer laminate sheet. 
         FIG. 2  is an elevation view of the multi-layer laminate sheet. 
         FIG. 3  is a perspective view of an open pouch. 
         FIG. 4  is an elevation view of a closed, but not yet sealed pouch. 
         FIG. 5  is a perspective view depicting the placement of an electrode assembly within the pouch. 
         FIG. 6  is a top view of a pouch superimposed with an alternative multi-layer laminate sheet, according to another embodiment of the invention. 
         FIG. 7  is a flow chart of the operations performed to manufacture a battery pack. 
     
    
    
     DETAILED DESCRIPTION 
     Several embodiments of the invention with reference to the appended drawings are now explained. Whenever the shapes, relative positions, and other aspects of the parts described in the embodiments are not clearly defined, the scope of the invention is not limited only to the parts shown, which are meant merely for the purpose of illustration. Also, while numerous details are set forth, it is understood that some embodiments of the invention may be practiced without these details. In other instances, well-known circuits, structures, and techniques have not been shown in detail so as not to obscure the understanding of this description. 
       FIG. 1  and  FIG. 2  show a multi-layer laminate sheet  10  that may be used to form a pouch type case for a battery such as a lithium ion polymer battery (also referred to as a lithium polymer battery). The multi-layer material  10  may have an inner sealant layer  11 , a core layer  12 , and an outer insulating layer  13 . The core layer  12  has a width W 1 . The inner sealant layer  11  may have the same width W 1  as the core layer  12 . The width W 1  is chosen according to the particular design of the battery. The outer insulating layer  13  has a width W 2  that is greater than the width W 1  of the core layer  12 , such that the opposing left and right edges of the outer layer  13  as shown extend far enough past the opposing left and right edges of the core layer  12 , respectively, to provide adequate insulation for the edges of the core layer  12 . For example, the edges of the outer layer  13  may extend approximately 0.1 to 0.5 millimeters past the respective edges of the core layer  12 , making the width W 2  of the outer layer  13  approximately 0.2 to 1 millimeter greater than the width W 1  of the core layer  12 . 
     The inner sealant layer  11  may be a polyolefin-based polymer. The inner sealant layer  11  directly contacts an electrode assembly. It serves to electrically shield the electrode assembly by virtue of the heat fusion and insulation properties of the polymer. Examples of the polyolefin-based polymer include, but are not limited to, polypropylene, chlorinated polypropylene, polyethylene, ethylene-propylene copolymer, polyethylene-acrylic acid copolymer, and polypropylene-acrylic acid copolymer. In particular, casting polypropylene film (CPP) may be used as the inner sealant layer  11 . The inner sealant layer  11  may have a thickness in the range of 30 to 150 microns. 
     The core layer  12  is interposed between the inner sealant layer  11  and the outer insulating layer  13 . It may be made of a metal foil and serves as a substrate, which prevents moisture and air from penetrating the pouch and maintains the strength of the laminate sheet  10 . Examples of material that may be used to form the metal foil include aluminum, nickel, and steel. The core layer  12  may have a thickness in the range of 20 to 150 microns. 
     The outer insulating layer  13  provides insulation to protect the other layers, particularly the core layer  12 , of the laminate sheet. Examples of a polymer that may be used as the outer layer  13  include nylon, particularly, oriented nylon film. The outer layer  13  may have a thickness in the range of 15 to 25 microns. 
     To form the multi-layer sheet  10 , the core layer  12  is prepared to have a width that is appropriate for a cell design of an electrode assembly that is to be enclosed by the pouch. The inner layer  11  may be prepared to have the same width as the core layer  12 . The outer layer  13  is prepared to have a width that is wider than the width of the core layer  12 . The inner layer  11  is positioned against one surface of the core layer  12 . The outer layer  13  is positioned against the other surface of the core layer  12 , such that the edges of the outer layer  13  extend past the edges of the core layer  12 . The layers may then be bonded together using, for example, dry lamination, heat lamination, or extrusion lamination. For instance, an adhesive may be interposed between one layer and another layer and then allowed to dry. The adhesive may be an adhesive such as urethane resin, which has an adhesion and tensile strength that prevents interlayer separation over time and prevents the pouch from being damaged by external impacts. The layers are then bonded to each other using a heating roll under a predetermined pressure at a temperature higher than room temperature. Alternatively, the layers may be bonded to each other using a pressure roll under a predetermined pressure at room temperature. 
       FIG. 3  and  FIG. 4  show a pouch type case  20  that may be constructed from the multi-layer laminate sheet  10 . To create the pouch  20 , a cavity  21  may be formed in the laminate sheet  10 , and the laminate sheet  10  is folded to create a top section  22  that covers the cavity  21 . In one embodiment, first and second sections of the sheet are folded about a fold line that is substantially perpendicular to the opposing edges of the sheet  10 , as shown in  FIG. 3 . The cavity  21  and the top section  22  are created such that the inner sealant layer  11  forms the interior surface of the pouch  20  and the outer insulating layer  13  forms the exterior surface of the pouch  20 . The cavity  21  has a predetermined width and depth for receiving an electrode assembly  30 , as shown in  FIG. 5 . 
     After placing the electrode assembly  30  in the cavity  21 , the top section  22  and the margin  23  of the sheet  10  surrounding the cavity  21  may be bonded together to seal the pouch, as shown in  FIG. 4 . The pouch  20  may be heat sealed along three sides of the pouch  20  as shown. A fourth side of the pouch  20  is typically formed by the folding of the pouch  20  to create the top section  22  and thus does not require heat sealing. To enclose the electrode assembly  30  and seal the pouch  20 , the peripheral portion of the inner sealant layer  11  at the top section  22  and the portion of the inner sealant layer  11  at a flange or margin  23  may be bonded to each other to result in a completely sealed pouch  20 . 
     In another embodiment, the pouch may be created from two separate multi-layer laminate sheets  10 . A cavity may be formed in one of the two sheets. The other sheet may be used as the top section of the pouch that covers the cavity. After placing the electrode assembly in the cavity, the top section and the margin of the sheet surrounding the cavity may be bonded together to seal the pouch. In this case, the pouch may be heat sealed along four sides of the pouch. To enclose the electrode assembly and seal the pouch, the peripheral portion of the inner sealant layer of the top section and the inner sealant layer of the margin may be bonded to each other to result in a completely sealed pouch. 
     In yet another embodiment, cavities may be formed in both the top section and the bottom section of the pouch. In one embodiment, the multi-layer laminate sheet may be folded about a fold line that is substantially perpendicular to the opposing edges of the sheet to create the top section and the bottom section. In another embodiment, two separate sheets may be used for the top section and the bottom section. The cavity of each section may, for example, have a depth that is one-half the height of the electrode assembly. After placing the electrode assembly in the cavity of the bottom section, the cavity of the top section may be positioned over the electrode assembly. The margin of the top section surrounding the top cavity and the margin of the bottom section surrounding the bottom cavity may be bonded together to seal the pouch. To enclose the electrode assembly and seal the pouch, the portion of the inner sealant layer at the margin of the top section and the portion of the inner sealant at the margin of the bottom section may be bonded to each other to result in a completely sealed pouch. 
     Note that while the figures here show the sheet  10  having the “overhanging” peripheral sections of the insulating layer  13  at the two opposing sides  24 _L,  24 _R of the pouch  20  (see for example  FIG. 3 ), the sheet  10  could also be prepared so as to have a further overhanging section at its end  25 . The latter is the cut end of the pouch  20 , opposing the end through which the fold line runs (see  FIG. 3 ). 
       FIG. 3  shows the pouch  20  as having substantially straight sides  24 _L,  24 _R, and a substantially straight end  25 . However, when the cavity  21  is formed in the multi-layer laminate sheet  10  with each layer having substantially straight edges, the sides  24 _L,  24 _R, and the end  25  of the pouch  20  may not be straight. Rather, the margin  23  may have a variable width around the cavity  21 , where the width is dependent upon the shape and size of the cavity. The variable width of the margin  23  may cause the sides  24 _L,  24 _R, and end  25  to have a wavy shape, and thus the edges of the bottom section of the pouch  20  may not align with the edges of the top section  56 . The multi-layer laminate sheet may be designed and manufactured to have a shape that compensates for this effect. The sheet may have a shape such that when the cavity is formed in the sheet, the sides  24 _L,  24 _R, and end  25  will be substantially straight and align with the edges of the top section  56 . The shape of the sheet may be dependent upon the shape and size of the cavity that is to be formed in the sheet. 
       FIG. 6  shows an example of the pouch  20  having a variable width margin  23 . In  FIG. 6 , the sides  24 _L,  24 _R, and the end  25  of the pouch  20  may be wavy with the margin  23  being narrower around the sides of the cavity  21 , as compared to the margin  23  around the corners of the cavity  21 . This is due to more sheet material being pulled into the center of the cavity  21  to form the cavity  21 . To compensate for this effect, the sheet in which the cavity  21  is to be formed, referred to here as a sheet  50  (shown by the dotted line), may be manufactured such that the sheet  50  is narrower near the corners  51 ,  52  of the sheet  50 , and wider towards the center of each side  54 _R,  54 b_L of the sheet  50  before forming the cavity  21 . The sheet  50  may have a shorter length near the corners  51 ,  52  and a longer length at the center of the end  55 . The sheet  50  has an overhanging outer insulating layer (not shown) and a core layer (not shown), with each layer having a shape similar to the sheet  50  that is shown in  FIG. 6 . The opposing left and right edges of the outer insulating layer extend far enough past the opposing right and left edges of the core layer, respectively, to provide adequate insulation for the edges of the core layer. When a cavity is formed in the sheet  50 , more sheet material may be pulled into the center of the cavity  21  from the center of the sides  54 _L,  54 _R and end  55  of the sheet  50  to form the cavity  21 . This may result in a pouch with a cavity section that has substantially straight sides and ends (unlike the pouch  20  shown in  FIG. 6 ). After the cavity  21  is formed and the sheet  50  is folded along the fold line to form a top section  56 , the sides  54 _L,  54 _R and end  55  of the cavity section will align with the straight edges of the top section  56 . Thus, the edges of the overhanging outer insulating layer at the cavity section will align with the edges of the overhanging outer insulating layer at the top section  56 , thereby preventing the core layer from being exposed around the edges of the pouch and providing electrical insulation for the core layer. The sheet  50  may be designed to have a shape other than that shown in  FIG. 6 , depending on the size and shape of the cavity  21 . 
     As shown in  FIG. 4 , the sealed pouch  20  has portions of the outer insulating layer  13 , at the top section  22  and at the cavity  21 , extending past the edges of the core layer  12  (in the top section  22  and in the cavity  21 ). This prevents the core layer  12  from being exposed around the edges of the pouch  20  and thus provides electrical insulation for the core layer  12 , without manual processing of the pouch  20  by, for example, folding and taping the sealed edges to the side of the pouch  20 . Eliminating the tape may reduce the overall height of the battery pack by about 50 microns and the overall width by about 100 microns. This may contribute about 1% to 2% additional energy density (by virtue of fitting a larger battery cell and electrode assembly). The extended portions of the outer insulating layer  13  may be folded inward (in the direction of the arrows shown in  FIG. 4 ) and heat sealed or otherwise bonded together (or to the side of the pouch  20 ), to provide further protection for the core layer  12 . 
     Referring to  FIG. 5 , the pouch  20  may enclose an electrode assembly  30 . The electrode assembly  30  includes a positive electrode plate  31  that has a coating made of positive active materials and a negative electrode plate  32  that has a coating made of negative active materials. An electrolyte separator  33  may be positioned between the positive electrode plate  31  and the negative electrode plate  32 , to prevent a short circuit between the positive electrode plate  31  and the negative electrode plate  32  and allowing only appropriate chemical transport between the positive electrode plate  31  and the negative electrode plate  32 . Electrode assemblies of other suitable battery chemistries are possible. 
     A positive electrode tab  34  is bonded to the positive electrode plate  31  and protrudes for a predetermined length to extend outside of the pouch. Similarly, a negative electrode tab  35  is bonded to the negative electrode plate  32  and protrudes for a predetermined length to extend outside of the pouch. The positive electrode tab  34  and the negative electrode tab  35  may be made of materials such as aluminum, copper, or nickel. The tabs  34  and  35  should have sufficient thickness and size to carry a substantial amount of current without any appreciable voltage drop. 
     Insulating sleeves  36  may be installed on the positive electrode tab  34  and the negative electrode tab  35  to prevent a short circuit between the electrode tabs  34  and  35  and the core layer  12  of the pouch  20  (at the outside edge of the margin  23 ). The insulating sleeves  36  should form a hermetic seal, to prevent air and moisture from entering the pouch  20  and electrolyte from leaking out of the pouch  20 . 
       FIG. 7  is a flow chart of the operations performed to manufacture a battery pack using the multi-layer sheet  10 . Manufacturing the battery pack includes preparing the multi-layer laminate sheet  10  (block  40 ), preparing the pouch  20  (block  41 ), installing the electrode assembly  30  (block  42 ), and sealing the pouch  20  (block  43 ). These operations have been described in detail above. 
     For purposes of explanation, specific embodiments were described to provide a thorough understanding of the present invention. These should not be construed as limiting the scope of the invention but merely as illustrating different examples and aspects of the invention. It should be appreciated that the scope of the invention includes other embodiments not discussed in detail above. Various other modifications, changes, and variations which will be apparent to those skilled in the art may be made in the arrangement, operation, and details of the apparatus and methods of the present invention disclosed herein without departing from the spirit and scope of the invention as defined in the appended claims. For instance, while  FIG. 5  shows a pouch  20  as containing an electrode assembly  30 , the pouch  20  may alternatively be used to house multiple cells each of which may have been separately sealed. Therefore, the scope of the invention should be determined by the claims and their legal equivalents. Such equivalents include both currently known equivalents as well as equivalents developed in the future, i.e., any elements developed that perform the same function, regardless of structure. Furthermore, no element, component, or method step is intended to be dedicated to the public regardless of whether the element, component, or method step is explicitly recited in the claims.

Metadata:
Filing Date: 20110701
Publication Date: 20140429
Grant Date: 20140429
Priority Date: 20110701
Inventors: ROY LOREN L.
Assignee: APPLE INC
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Family ID: 47391000