PATENT DOCUMENT

Publication Number: US-11431047-B2
Application Number: US-201816040719-A
Country: US
Kind Code: B2

Title: Feedthrough with integrated insulator

Abstract:
The disclosed technology relates to an electrical feedthrough for a battery cell. The electrical feedthrough may include a rivet, an outer gasket, an inner gasket, a terminal and an insulator. The rivet compresses the outer gasket, inner gasket, and terminal to create a hermetic seal at an opening through an enclosure of the battery cell. The inner gasket includes a recessed portion for seating of the terminal to prevent rotation of the terminal with respect to the inner gasket, a protrusion for engaging a corresponding notch on the terminal to further prevent rotation of the terminal with respect to the inner gasket, and a mating surface for attaching to the insulator to align and position the insulator within the enclosure. The insulator is positioned between the battery cell and the inner gasket to prevent physical and electrical contact between the set of layers and the feedthrough.

Claims:
What is claimed is: 
     
       1. A battery cell, comprising:
 a set of layers comprising a cathode layer, an anode layer, and a separator layer disposed between the cathode layer and the anode layer; 
 an enclosure enclosing the set of layers, the enclosure comprising an opening for receiving a feedthrough, the feedthrough comprising: 
 a rivet comprising a planar head at an end, a shank extending therefrom, and a deformable tail at an opposite end, the rivet formed of a conductive material; 
 an outer gasket disposed adjacent to the planar head of the rivet, the outer gasket formed of an insulating material and comprising an opening for receiving the shank of the rivet, and a collar; 
 an inner gasket disposed on the collar of the outer gasket, the inner gasket formed of an insulating material and comprising an opening for receiving the collar of the outer gasket, a recessed area, an insulator mating surface, and an anti-rotation protrusion; 
 a terminal disposed within the recessed area of the inner gasket, the terminal formed of a conductive material and comprising an opening for receiving the shank of the rivet and a notch for engaging the anti-rotation protrusion of the inner gasket; 
 an insulator supported by the insulator mating surface of the inner gasket, the insulator formed of an insulating material; and 
 an adhesive layer, the adhesive layer disposed between the insulator and the insulator mating surface of the inner gasket, wherein the insulator is bonded to the insulator mating surface of the inner gasket by the adhesive layer. 
 
     
     
       2. The battery cell of  claim 1 , wherein the insulator further comprises a first notch for the tab to extend therethrough, and a second notch for a second tab to extend therethrough, the second tab extending from the set of layers. 
     
     
       3. The battery cell of  claim 1 ,
 wherein the inner gasket is composed of a pigmented polymer; 
 wherein the insulator is composed of a transparent polymer; and 
 wherein the insulator is welded to the mating surface of the inner gasket through a laser transmission welding operation. 
 
     
     
       4. The battery cell of  claim 3 , wherein a wavelength of the laser is in a range of about 800 nm to about 2000 nm. 
     
     
       5. The battery cell of  claim 1 , wherein the mner gasket comprises a perfluoroalkoxy (PF A) material. 
     
     
       6. The battery cell of  claim 1 , wherein the insulator comprises at least one of a polypropylene, PF A, Polyimide and polyethylene terephthalate material. 
     
     
       7. The battery cell of  claim 1 , further comprising a tab that extends from the set of layers, wherein the tab is electrically coupled to the terminal and the rivet to form an external battery terminal at the rivet. 
     
     
       8. The battery cell of  claim 1 , wherein the insulator is disposed between the set of layers and the inner gasket to prevent physical contact between the set of layers and the feed through. 
     
     
       9. A battery feedthrough, comprising:
 a rivet comprising a planar head at an end, a shank extending therefrom, and a deformable tail at an opposite end, the rivet formed of a conductive material; 
 an outer gasket disposed adjacent to the planar head of the rivet, the outer gasket formed of an insulating material and comprising an opening for receiving the shank of the rivet, and a collar; 
 an inner gasket disposed on the collar of the outer gasket, the inner gasket formed of an insulating material and comprising an opening for receiving the collar of the outer gasket, a recessed area, an insulator mating surface, and an anti-rotation protrusion; 
 a terminal disposed within the recessed area of the inner gasket, the terminal formed of a conductive material and comprising an opening for receiving the shank of the rivet and a notch for engaging the anti-rotation protrusion of the inner gasket; 
 an insulator supported by the insulator mating surface of the inner gasket, the insulator formed of an insulating material; and 
 an adhesive layer, the adhesive layer disposed between the insulator and the insulator mating surface of the inner gasket, wherein the insulator is bonded to the insulator mating surface of the inner gasket by the adhesive layer. 
 
     
     
       10. The battery feedthrough of  claim 9 ,
 wherein the inner gasket is composed of a pigmented polymer; 
 wherein the insulator is composed of a transparent polymer; and 
 wherein the insulator is welded to the insulator mating surface of the inner gasket through a laser transmission welding operation. 
 
     
     
       11. The battery feedthrough of  claim 10 , wherein a wavelength of the laser transmission is in a range of about 800 nm to about 2000 nm. 
     
     
       12. The battery feedthrough of  claim 9 , wherein the inner gasket comprises a perfluoroalkoxy (PFA) material. 
     
     
       13. The battery feedthrough of  claim 9 , wherein the insulator comprises at least one of a polypropylene, PF A, Polyimide and polyethylene terephthalate material. 
     
     
       14. The battery feedthrough of  claim 9 , wherein the planar head of the rivet is configured to form an external terminal of a battery. 
     
     
       15. The battery feedthrough of  claim 9 , wherein the insulator is configured to prevent physical contact between one or more cells of a battery and one or more of the terminal and the rivet of the battery feedthrough.

Description:
PRIORITY 
     This application claims the benefit under 35 U.S.C. § 119(e) of U.S. Provisional Patent Application Ser. No. 62/667,713, entitled “FEEDTHROUGH WITH INTEGRATED INSULATOR,” filed on May 7, 2018, which is incorporated herein by reference in its entirety. 
    
    
     TECHNICAL FIELD 
     The present disclosure relates generally to battery cell feedthroughs, and more particularly, to a battery cell feedthrough with an integrated insulator. 
     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 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 from the enclosure to prevent shorting of the battery cells. Conventional insulator materials include glass, and ceramics that inhibit conduction of electrical energy. Further, the enclosure enclosing the electrodes may be filled with electrolyte thereby requiring the electrical feedthrough to provide a hermetically seal to prevent unwanted leakage or failure. 
     In some variations, a welding process may be used to physically couple the electrical feedthrough to a wall of the enclosure. Welding may complicate assembly of the battery cell and may further require additional space on the enclosure to accommodate a proper weld, thereby reducing packaging efficiency. In addition, welding may cause heat-induced stresses in a feedthrough that may compromise the sealing integrity of the feedthrough. 
     SUMMARY 
     The disclosed embodiments provide for a battery cell enclosed within an enclosure that utilizes a riveted feedthrough. The feedthrough includes a rivet, an outer gasket, an inner gasket, a terminal and an insulator. The rivet compresses the outer gasket, inner gasket, and terminal to create a seal at an opening in the enclosure. The inner gasket includes a recessed portion for seating of the terminal, a mating surface for attaching to the insulator, and a protrusion for engaging a corresponding notch on the terminal to prevent rotation of the terminal with respect to the inner gasket. The insulator prevents physical contact between electrodes within the enclosure and the feedthrough. 
     In some embodiments, a battery feedthrough includes a rivet comprising a planar head at an end, a shank extending therefrom, and a deformable tail at an opposite end. The feedthrough also includes an outer gasket disposed adjacent to the planar head of the rivet. The outer gasket includes an opening for receiving the shank of the rivet, and a collar. The feedthrough also includes an inner gasket disposed on the collar of the outer gasket. The inner gasket includes an opening for receiving the collar of the outer gasket, a recessed area, an insulator mating surface, and an anti-rotation protrusion. The feedthrough also includes a terminal disposed within the recessed area of the inner gasket. The terminal includes an opening for receiving the shank of the rivet and a notch for engaging the anti-rotation protrusion of the inner gasket. The feedthrough also includes an insulator supported by the insulator mating surface of the inner gasket. 
     In some embodiments, a method for manufacturing a battery cell is disclosed. The method includes sliding a rivet within an opening of an outer gasket, sliding the outer gasket within an opening disposed on a wall of an enclosure. The enclosure protects a set of layers that includes a cathode layer, an anode layer, and a separator layer disposed between the cathode layer and the anode layer. The method also includes inserting an inner gasket over a collar of the outer gasket and against an inside surface of the enclosure. The inner gasket includes a recessed portion, a mating surface, and an anti-rotation protrusion. The method further includes seating a terminal within the recessed portion of the inner gasket and onto the rivet. The terminal includes a notch for engaging the anti-rotation protrusion of the inner gasket to prevent rotation of the terminal with respect to the inner gasket. The method also includes deforming an end of the rivet to create a hermetic seal at the opening of the enclosure, welding a cathode tab extending from the cathode layer to the terminal, welding an anode tab extending from the anode layer to the enclosure, closing the enclosure to completely enclose the set of layers, and filling the enclosure with electrolyte. 
    
    
     
       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 a perspective view of an assembled battery, in accordance with various aspects of the subject technology; 
         FIG. 2A  illustrates an exploded view of a feedthrough, in accordance with various aspects of the subject technology; 
         FIG. 2B  illustrates an alternative exploded view of a feedthrough, in accordance with various aspects of the subject technology; 
         FIG. 3  illustrates a perspective view of a rivet, in accordance with various aspects of the subject technology; 
         FIG. 4A  illustrates a perspective view of an outer gasket, in accordance with various aspects of the subject technology; 
         FIG. 4B  illustrates a cross-section view of an outer gasket, in accordance with various aspects of the subject technology; 
         FIG. 5  illustrates a perspective view of a terminal, in accordance with various aspects of the subject technology; 
         FIG. 6  illustrates a perspective view of an insulator, in accordance with various aspects of the subject technology; 
         FIG. 7A  illustrates a perspective view of an inner gasket, in accordance with various aspects of the subject technology; 
         FIG. 7B  illustrates a cross-section view of an inner gasket, in accordance with various aspects of the subject technology; 
         FIG. 8  illustrates a perspective partial-section view of an assembled battery, in accordance with various aspects of the subject technology; 
         FIG. 9A  illustrates a top view of an assembled battery, in accordance with various aspects of the subject technology; 
         FIG. 9B  illustrates a partial-section view of an anode terminal, in accordance with various aspects of the subject technology; 
         FIG. 9C  illustrates a partial-section view of a cathode tab welded to a terminal, in accordance with various aspects of the subject technology; 
         FIG. 9D  illustrates a partial-section view of a cathode feedthrough, in accordance with various aspects of the subject technology; 
         FIG. 10A  illustrates a front view of an assembled battery, in accordance with various aspects of the subject technology; 
         FIG. 10B  illustrates a partial-section view of an assembled battery, in accordance with various aspects of the subject technology; 
         FIG. 11  illustrates a cross-section view of an assembled battery, in accordance with various aspects of the subject technology; 
         FIG. 12  illustrates a portable electronic device, in accordance with various aspects of the subject technology; and 
         FIG. 13  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 enclosure to be hermetically sealed to prevent unwanted leakage or failure. In addition, electrical feedthroughs must insulate the electrical connection to the cathode electrodes from the enclosure to prevent shorting of the battery cells. 
       FIG. 1  illustrates a perspective view of an assembled battery  100 , in accordance with various aspects of the subject technology. The battery  100  comprises an enclosure  110 , a feedthrough  120 , a terminal  130  and port  140 . The enclosure  110  may comprise a metal, such as aluminum or an aluminum alloy, and may have a non-corrosive coating line the interior of the enclosure  110 . The enclosure  110  is configured to enclose and protect one or more cells disposed within the enclosure. In one aspect, the enclosure  110  may comprise a top portion and a bottom portion. The top portion may be configured to form a cup or open cube, cuboid, cylinder, prism, cone, pyramid or combination thereof, to receive the one or more battery cells. The bottom portion may be configured to completely enclose the one or more battery cells, and may be bonded, glued, welded, mechanically fastened or coupled, to the top portion. For example, the top portion and bottom portion of the enclosure  110  may be welded together at a periphery by welding together flanges on the top portion and the bottom portion, respectively. In another example, the top portion and bottom portion of the enclosure  110  may be welded together at a periphery by welding together a joggled overlap between the top portion and the bottom portion. In yet another example, the top portion and bottom portion of the enclosure  110  may be welded together at a periphery by welding together an overlap between the top portion and the bottom portion. 
     Each battery cell may comprise at least one cathode layer with an active coating, a separator, and at least one an anode layer with an active coating, as discussed with reference to  FIG. 11 . A tab may extend from each of the anode and cathode layers, as discussed further below. The terminal  130  may comprise a weld pad that is configured to be electrically connected or coupled to a tab extending from the anode layer. The port  140  may comprise an opening disposed within the enclosure  110  for receiving electrolyte. After the enclosure  110  is sufficiently filled with electrolyte, the port  140  may be welded or sealed shut to prevent leakage of the electrolyte, as discussed further below. 
       FIGS. 2A and 2B  illustrate exploded views of the feedthrough  120 , in accordance with various aspects of the subject technology. The feedthrough  120  may comprise a rivet  221 , an outer gasket  222 , an inner gasket  224 , a terminal  226  and an insulator  228 . The rivet  221  is configured to compress the outer gasket  222 , inner gasket  224 , and terminal  226  to create a seal at an opening  112  on a wall of the enclosure  110 . The feedthrough  120  does not require welding to the enclosure because it utilizes a compression force generated by the rivet  221  to create a hermetic seal at the opening  112 . In addition, because no welding is required, packaging efficiency for the battery  100  is improved because there is no need to accommodate a weld along a wall of the battery  100 . Further, as described below, the feedthrough  120  implements a multitude of anti-rotation features to reduce and mitigate the risk that an electrical short may occur between the feedthrough  120  and the enclosure  110 , as the enclosure  110  may have an anode potential and the feedthrough  120  may have a cathode potential. By mitigating or eliminating the risk of an electrical shortage, reliability of the battery  100  is greatly improved. 
       FIG. 3  illustrates a perspective view of the rivet  221 , in accordance with various aspects of the subject technology. The rivet  221  may comprise a planar head  310  at an end, a shank  315  extending therefrom, and a deformable tail  320  at an opposite end. Prior to installation, the deformable tail  320  may have a diameter that is substantially equal to or less than a diameter of the shank  315  extending from the planar head  310  (as shown in  FIGS. 2A and 2B ). The deformable tail  320  of the rivet  221  is configured to expand in diameter after the rivet  221  is installed (as shown in  FIGS. 8, 9D and 10B ), to thereby compress the components sandwiched between the planar head  310  and the deformable tail  320 . In one aspect, the compression force generated by the rivet  221  is sufficient to create a hermetic seal at the opening  112 , as well as prevent undesired rotation of the rivet  221  within the opening  112 , inner gasket  224  within the enclosure  110 , and/or terminal  226 . The compression force generated by the rivet  221  may, for example, cause a compression stress of approximately 10-40 MPa acting on the outer gasket  222  and inner gasket  224 . The rivet  221  may comprise a metal or alloy that is readily deformable, such as an aluminum alloy. 
       FIGS. 4A and 4B  illustrate a perspective view and a cross-section view, respectively, of the outer gasket  222 , in accordance with various aspects of the subject technology. The outer gasket  222  may be disposed adjacent to the planar head  310  of the rivet  221 . The outer gasket  222  may comprise a recessed area  410  disposed at a proximal end of the outer gasket  222 , an opening  420  for receiving the shank of the rivet  221 , and a collar  430  disposed at a distal end of the outer gasket  222  surrounding a portion of the opening  420 . The recessed area  410  may be sized to accommodate a portion of the planar head  310  of the rivet  221 . The outer gasket  222  may comprise a polymer, such as perfluoroalkoxy (PFA), or other material capable of insulating electrical energy. In one aspect, the outer gasket  222  surrounds the rivet  221  to electrically insulate the rivet  221  from the enclosure  110 , as shown in  FIGS. 9D and 10B . 
       FIGS. 7A and 7B  illustrate a perspective view and cross-section view, respectively, of the inner gasket  224 , in accordance with various aspects of the subject technology. The inner gasket  224  may be disposed on the collar  430  of the outer gasket  222 . The inner gasket  224  may comprise an opening  710  for receiving the collar  430  of the outer gasket  222 , a protrusion  720  for engaging a corresponding notch on the terminal  226  to prevent rotation of the terminal  226  with respect to the inner gasket  224 , a recessed portion  730  for seating of the terminal  226  to prevent rotation of the terminal  226  with respect to the inner gasket  224 , and a mating surface  740  for attachment to the insulator  228 . The inner gasket  224  may comprise a polymer, such as a pigmented polymer, and may, for example, comprise PFA, or other material capable of insulating electrical energy. In one aspect, the inner gasket  224  electrically insulates the terminal  226  from the enclosure  110 , as shown in  FIGS. 9D and 10B . 
     In one aspect, the protrusion  720  may comprise a step or ledge that is configured to engage a corresponding edge or surface of the terminal  226  to prevent rotation of the terminal  226  with respect to the inner gasket  224 . For example, the step or ledge of the protrusion  720  may mechanically engage and interfere with the edge or surface of the terminal  226  to prevent inadvertently movement or rotation of the terminal  226  about a center axis of the rivet  221 , thereby preventing contact or shorting with an inside surface of the enclosure  110 . 
     In another aspect, the recessed portion  730  may completely or partially surround the terminal  226  to further prevent rotation of the terminal  226  with respect to the inner gasket  224 . For example, the recessed portion  730  may comprise a recessed area surrounding by at least one side wall  750 . The side wall  750  prevents one or more edges of the terminal  226  from moving or rotating independently from the inner gasket  224  because the side wall  750  surrounding the recessed area mechanically engages and prevents the terminal  226  from inadvertently moving or rotating about a center axis of the rivet  221 , thereby preventing contact or shorting with an inside surface of the enclosure  110 . In one aspect, the side wall  750  may have a drafted profile, as shown in  FIG. 7B . 
     In some aspects, the inner gasket  224  may be sized to contact or to come in close proximity to one or more inside surfaces of the enclosure  110 . By minimizing gaps between the inside surfaces of the enclosure  110  (top, bottom, and/or sides) and the inner gasket  224 , rotation of the inner gasket  224  with respect to the enclosure  110  is also minimized, thereby improving reliability of the feedthrough  120  because unnecessary motion or rotation of the rivet  221  within the opening  112 , inner gasket  224  within the enclosure  110 , and/or terminal  226 , may jeopardize or compromise the hermetic seal created by the compression force of the rivet  221 . For example, the inner gasket  224  may have one or more protrusions  760  extending outwardly from sides of the inner gasket  224  to increase a length of the inner gasket  224  and thereby increase a contact area with the inside surface of the enclosure  110 . The protrusion  760  may extend outwardly from a lateral side of the inner gasket  224  and be disposed adjacent to a corner or edge of the inner gasket  224 . As shown in  FIG. 7A , a first protrusion  760  may extend from a top-right corner and a separate protrusion  760  may extend from a top-left corner. In one aspect, by disposing the protrusions  760  on opposite sides and corners of the inner gasket  224 , the inner gasket  224  has an increased surface area in contact with the inside surface of the enclosure  110 , thereby preventing rotation of the inner gasket  224  with respect to the enclosure  110 . 
     Referring to  FIG. 5 , a perspective view of the terminal  226  is illustrated, in accordance with various aspects of the subject technology. The terminal  226  may be disposed within the recessed portion  730  of the inner gasket  224 . The terminal  226  may comprise a notch  510  for engaging the protrusion  720  of the inner gasket  224 , and an opening  520  for receiving the shank of the rivet  221 . The terminal  226  may comprise a coupling region  530  for electrically coupling to a tab extending from the one or more battery cells enclosed within the enclosure  110 , as shown in  FIGS. 9C and 10B . The tab extending from the one or more battery cells may, for example, by spot welded to the coupling region  530 . The terminal  226  may comprise a metal or alloy, or material that is capable of conducting electricity. When coupled to the tab extending from the one or more battery cells, electrical energy from the cathode electrodes, for example, passes through the terminal  226  to the rivet  221  to thereby provide an external terminal for the battery cell at the planar head  310  of the rivet  221 . 
     The terminal  226  also comprises a compression region  540  for contacting the deformable tail  320  of the rivet  221  when the deformable tail  320  of the rivet  221  is expanded and the rivet  221  is in an installed or deployed configuration. In one aspect, the compression region  540  is adequately sized to handle the compression force generated by the rivet  221 . The compression region  540  may, for example, have a minimum area of about 0.44 mm, sufficient to support a rivet head having a diameter of about 1.15 mm. 
       FIG. 6  illustrates a perspective view of the insulator  228 , in accordance with various aspects of the subject technology. The insulator  228  may be disposed directly on the mating surface  740  of the inner gasket  224  and between the one or more battery cells  810  and the inner gasket  224 , to prevent physical contact between the one or more battery cells  810  and the terminal  226  or rivet  221  of the feedthrough  120 , as shown in  FIGS. 9D and 10B . A material of the insulator  228  may comprise a polypropylene, PFA, Polyimide, polyethylene terephthalate, or other material that may be used to insulate electrical energy. 
     The insulator  228  may comprise a first notch  610 A to accommodate pass-through of a first tab  820 A extending from the one or more battery cells  810  (as shown in  FIG. 9C ), and a second notch  610 B to accommodate pass-through of a second tab  820 B extending from the one or more battery cells  810  (as shown in  FIG. 9B ). The insulator  228  may also comprise a filling notch  620  to allow electrolyte to flow through the port  140  and into the enclosure  110 . 
     In one aspect the insulator  228  is bonded to the mating surface  740  of the inner gasket  224  to maintain a relationship between the insulator  228  and the inner gasket  224 . In one example, a layer of adhesive may be disposed between the mating surface  740  of the inner gasket  224  and the insulator  228  to glue the insulator  228  into position between the one or more battery cells and the feedthrough  120 . In another example, the insulator  228  may be welded to the mating surface  740  of the inner gasket  224  through a laser transmission welding operation. In this example, the insulator  228  may comprise a transparent polymer and the inner gasket  224  may comprise a pigmented polymer. A laser having a wavelength in a range of about 800 nm to about 2000 nm may be used to bond or weld the inner gasket  224  and the insulator  228  together. 
     Referring to  FIG. 8 , a perspective partial-section view of the assembled battery  100  is provided, in accordance with various aspects of the subject technology. The battery  100  comprises a battery cell  810  enclosed in the enclosure  110 . A first tab  820 A extending from a cathode electrode of the battery cell  810  passes through the first notch (not shown) of the insulator  228  and is welded to the terminal  226 . The terminal  226  is seated within the recess portion of the inner gasket  224 . The inner gasket  224  is disposed within the enclosure  110  and surrounds the collar of the outer gasket  222 . The rivet  221  is shown in a deployed configuration with the deformable tail expanded, thereby compressing the terminal  226 , inner gasket  224 , outer gasket  222 , and side wall of the enclosure  110  to create a hermetic seal at the opening  112 . 
       FIG. 9A  illustrates a top view of the assembled battery  100 , in accordance with various aspects of the subject technology. The battery  100  includes a terminal  130 , which may, for example, comprise an anode terminal; and a feedthrough  120 , which may, for example, comprise a cathode feedthrough. 
       FIG. 9B  illustrates a partial-section view of the anode terminal  130 , in accordance with various aspects of the subject technology. The battery cell  810  is enclosed within the enclosure  110 . The second tab  820 B extends from the battery cell  810  and may, for example, comprise an anode tab. The anode tab  820 B may extend through the second notch  610 B of the insulator  228 . The insulator  228  may be configured to prevent inadvertent contact, physical and/or electrical, between the battery cell  810  and the inside surface of the enclosure  110  and/or the anode tab  820 B. The anode tab  820 B may be welded by, for example, a spot-welding operation, to the inside surface of the enclosure  110 . Disposed on an outside surface of the enclosure  110  and directly opposite of the anode tab  820 B, may be the weld pad. 
       FIG. 9C  illustrates a partial-section view of a cathode tab welded to the terminal  226 , in accordance with various aspects of the subject technology. As shown, the battery cell  810  is enclosed within the enclosure  110 . The first tab  820 A extends from the battery cell  810  and may, for example, comprise a cathode tab. The cathode tab  820 A may extend through the first notch  610 A of the insulator  228 . The insulator  228  may be configured to prevent inadvertent contact, physical and/or electrical, between the battery cell  810  and the inside surface of the enclosure  110  and/or the cathode tab  820 A. The cathode tab  820 A may be welded by, for example, a spot-welding operation, to the coupling region  530  of the terminal  226 . As also shown in  FIG. 9C , the insulator  228  is mounted to or otherwise attached, welded, or bonded to the mating surface  740  of the inner gasket  224  to keep the insulator  228  in place. As also shown, the terminal  226  is disposed within the recessed portion  730  of the inner gasket  224 . 
       FIG. 9D  illustrates a partial-section view of the cathode feedthrough  120 , in accordance with various aspects of the subject technology. As shown, the battery cell  810  is enclosed within the enclosure  110 . The rivet  221  compresses the outer gasket  222 , inner gasket  224 , terminal  226 , and side wall of the enclosure  110  to create a hermetic seal at the opening  112 . The deformable tail  320  of the rivet  221  is shown in an expanded or deployed state and engages the compression region  540  of the terminal  226  at one end, while the planar head  310  of the rivet  221  acts upon the recessed area  410  of the outer gasket  222  at an opposite end. The insulator  228  prevents inadvertent physical or electrical contact between the battery cell  810  and the feedthrough  120 , and more specifically, prevents contact between the battery cell  810  and the rivet  221  or the terminal  226 . As also shown in  FIG. 9D , the insulator  228  is mounted to or otherwise attached, welded, or bonded to the mating surface  740  of the inner gasket  224  to keep the insulator  228  in place. 
       FIG. 10A  illustrates a front view of the assembled battery  100 , in accordance with various aspects of the subject technology. The battery  100  comprises the enclosure  110 , feedthrough  120 , terminal  130 , and port  140 .  FIG. 10B  illustrates a partial-section view of the assembled battery  100 , in accordance with various aspects of the subject technology. The battery cell  810  is enclosed within the enclosure  110 . The first tab  820 A is coupled to the terminal  226  and the second tab  820 B is coupled to the enclosure  110  at the terminal  130 . The insulator  228  prevents contact and provides electrical insulation between the battery cell  810  and the rivet  221 , terminal  226 , first tab  820 A and the second tab  820 B. The outer gasket  222  surrounds and insulates the rivet  221  as the rivet  221  passes through the enclosure  110 . The insulator  228  is mounted, bonded, welded, or otherwise affixed to the inner gasket  224  to maintain the position of the insulator  228  within the enclosure  110 . 
       FIG. 11  illustrates a cross-section view of the assembled battery  100 , in accordance with various aspects of the subject technology. The assembled battery  100  includes the battery cell  810  enclosure  110 , a battery management unit  1140 , and battery terminals  1150 . The battery management unit  1140  is configured to manage recharging of the battery cell  810 . The terminals  1150  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 a cathode with an active coating  1100 A, a separator  1110 , and an anode with an active coating  1100 B. For example, the cathode  1100 A may be an aluminum foil coated with a lithium compound (e.g., LiCoO 2 , LiNCoMn, LiCoAl or LiMn 2 O 4 ) and the anode  1100 B may be a copper foil coated with carbon or graphite. The separator  1110  may include polyethylene (PE), polypropylene (PP), and/or a combination of PE and PP, such as PE/PP or PP/PE/PP. The separator  1110  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 may be wound to form a jelly roll structure or can be stacked to form a stacked-cell structure. The plurality of layers are enclosed within enclosure  110  and immersed in an electrolyte  1120 , 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 cathode layers  1100 A of the plurality of layers are coupled to the first tab  820 A (not shown) through intermediate tabs (not shown) extending from each cathode layer  1100 A. The anode layers  1100 B of the plurality of layers are coupled to the second tab  820 B through intermediate tabs  1130  extending from each anode layer  1100 B. The first tab  820 A and the second tab  820 B extend from the battery cell  810  for electrical connection to other battery cells, the battery management unit  1140 , or other components as desired. As discussed above, the second tab  820 B may be electrically coupled to the enclosure at the terminal  130 . As also discussed above, the first tab  820 A may be electrically coupled to the feedthrough  120  (not shown). As further discussed above, the insulator  228  may be disposed between the battery cell  810  and the inside surface of the enclosure  110 . 
       FIG. 12  illustrates a portable electronic device  1200 , in accordance with various aspects of the subject technology. The above-described rechargeable battery  100  can generally be used in any type of electronic device. For example,  FIG. 12  illustrates a portable electronic device  1200  which includes a processor  1202 , a memory  1204  and a display  1208 , which are all powered by the battery  100 . Portable electronic device  1200  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  100  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 anti-rotation features and an insulator, as described above. 
       FIG. 13  illustrates an example method  1300  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  1310 , a rivet is slid within an opening of an outer gasket. At operation  1320 , the outer gasket is slid within an opening disposed on a wall of an enclosure. As described above, the enclosure configured to protect a set of layers that comprise a battery cell. The set of layers includes a cathode layer, an anode layer, and a separator layer disposed between the cathode layer and the anode layer. At operation  1330 , an inner gasket is inserted over a collar of the outer gasket and against an inside surface of the enclosure. As described above, the inner gasket includes a recessed portion, a mating surface, and an anti-rotation protrusion. 
     At operation  1340 , a terminal is seated within the recessed portion of the inner gasket and onto the rivet. The terminal comprises a notch for engaging the anti-rotation protrusion of the inner gasket to prevent rotation of the terminal with respect to the inner gasket. At operation  1350 , an end of the rivet is deformed to create a hermetic seal at the opening of the enclosure. In one aspect, to create a hermetic seal at the opening, a compressive force between a head of the rivet and the deformed end of the rivet is generated against the outer gasket, the wall of the enclosure, the inner gasket, and the terminal. 
     At operation  1360 , a cathode tab extending from the cathode layer is welded to the terminal. At operation  1370  an anode tab extending from the anode layer is welded to the enclosure. At operation  1380 , the enclosure is closed to completely enclose the set of layers. At operation  1390 , the enclosure is filled with electrolyte. 
     The method  1300  may further include bonding an insulator to the mating surface of the inner gasket so that the insulator is disposed between the set of layers of the battery cell and the inner gasket to prevent physical and/or electrical contact between the set of layers and the terminal or rivet. In one example, the insulator may be bonded to the mating surface of the inner gasket using an adhesive layer. In another example, the insulator may be welded to the mating surface of the inner gasket. In this example, the inner gasket may be composed of a pigmented polymer and the insulator may be composed of a transparent polymer. Welding of the insulator to the mating surface of the inner gasket may be accomplished using a laser transmission welding process to weld the insulator to the mating surface of the inner gasket. A wavelength that may be used for laser transmission welding may have a range of about 800 nm to about 2000 nm. 
     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: 20180720
Publication Date: 20220830
Grant Date: 20220830
Priority Date: 20180507
Inventors: PASMA, CHRISTOPHER R.
SHIU, BRIAN K.
Assignee: APPLE INC
CPC Classifications: [{"code": "H01M50/543", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01M50/145", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01M50/178", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01M50/566", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01M50/553", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01M50/586", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01M50/191", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01M50/119", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01M50/553", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01M10/0585", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01M50/586", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01M50/566", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01M50/586", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01M50/178", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01M50/545", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01M50/528", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01M50/119", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01M50/145", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01M50/191", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01M10/058", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01M50/553", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01M50/566", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01M50/119", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01M50/543", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01M50/191", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01M50/178", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01M50/103", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01M50/145", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01M50/116", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01M50/543", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01M50/172", "inventive": true, "first": true, "tree": "[]"}]
Family ID: 68383936