Layered electrochemical cell and manufacturing method therefor

• US 20040038090A1
• Filed: 06/05/2003
• Published: 02/26/2004
• Est. Priority Date: 06/05/2002
• Status: Active Grant

• Current Assignee: Reveo, Inc.
• Original Assignee: Reveo, Inc.
• Inventors: Faris, Sadeg M.
• Granted Patent: US 7,377,948 B2
• Time in Patent Office: Days
• US Class Current: 429/12
• CPC Class Codes: H01M 10/0436 Small-sized flat cells or batteries for portable equipment
• CPC Class Codes: H01M 8/00 Fuel cells; Manufacture thereof
• CPC Class Codes: H01M 8/2404 Processes or apparatus for grouping fuel cells
• CPC Class Codes: H01M 8/241 with solid or matrix-supported electrolytes
• CPC Class Codes: H01M 8/2465 Details of groupings of fuel cells
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y02E 60/50 Fuel cells
• CPC Class Codes: Y02P 70/50 Manufacturing or production processes characterised by the final manufactured product
• CPC Class Codes: Y10T 29/49108 Electric battery cell making
• CPC Class Codes: Y10T 29/49112 including laminating of indefinite length material

Abstract

Methods of the present invention are provided for forming a plurality of electrochemical cell layers, each cell layer generally including a pair of electrodes and a separator electrically insulating the pair of electrodes. Cells of a desired size are formed by slicing the laminar sheet through both opposing major surfaces. In certain embodiments, individual cells are defined by fill regions, filled with removable substances. Thus, when the cells are sliced, individual cells and in certain embodiments current collectors or conductors are exposed with minimal or no further processing. In other embodiments, fluid access channels or porous layers are filled with removable substances. Thus, when the cells are sliced, structural support is provided for the intended void regions.

Claims

1. A method of manufacturing an electrochemical cell comprising:

forming a plurality of cell layers into a laminar sheet having two opposing major surfaces, each cell layer including a pair of electrodes and a separator electrically insulating the pair of electrodes;

slicing the laminar sheet through both opposing major surfaces into a desired size.

2. The method of manufacturing an electrochemical cell as in claim 1, further forming a gas transport layer adjacent to at least one electrode having one or more voids.

3. The method of manufacturing an electrochemical cell as in claim 2, wherein the gas transport layer includes at least one channel.

4. The method of manufacturing an electrochemical cell as in claim 2, wherein the gas transport layer includes a porous layer.

5. The method of manufacturing an electrochemical cell as in claim 2, wherein the voids are filled with a removable substance prior to slicing the laminar sheet at a temperature below the melting point of the removable substance, further wherein the removable substance is allowed to melt thereby forming plural electrochemical cells having at least one gas flow layer with a void for gas access to the at least one electrode.

6. The method of manufacturing an electrochemical cell as in claim 2, wherein at least one of the electrochemical cell comprises a metal air electrochemical cell, wherein one of the electrodes in each electrochemical cell comprises a metal fuel, and the other electrode adjacent the gas transport layer in each electrochemical cell comprises an air diffusion electrode, further wherein a source of ion conducting electrolyte is provided.

7. The method of manufacturing an electrochemical cell as in claim 2, wherein at least one of the electrochemical cell comprises a metal air electrochemical cell, wherein one of the electrodes in each electrochemical cell comprises a metal fuel, the other electrode in each electrochemical cell comprises an air diffusion electrode, and the separator provides a source of ion conducting electrolyte.

8. The method of manufacturing an electrochemical cell as in claim 1, wherein at least one of the electrochemical cells comprises an electrical storage capacitor.

9. The method of manufacturing an electrochemical cell as in claim 8, wherein the capacitor comprises a symmetrical capacitor.

10. The method of manufacturing an electrochemical cell as in claim 9, wherein the electrodes are identical or substantially identical.

11. The method of manufacturing an electrochemical cell as in claim 10, wherein the electrodes comprise high surface area active material, further wherein electrolyte is provided.

12. The method of manufacturing an electrochemical cell as in claim 10, wherein the electrodes comprise Faradic psuedocapacitance materials, further wherein an electrolyte is provided.

13. The method of manufacturing an electrochemical cell as in claim 10, wherein the electrodes comprise high surface area active material and Faradic psuedocapacitance materials, further wherein an electrolyte is provided.

14. The method of manufacturing an electrochemical cell as in claim 10, wherein the electrodes comprise high surface area active material and hydrogel material, the hydrogel material comprising electrolyte therein.

15. The method of manufacturing an electrochemical cell as in claim 10, wherein the electrodes comprise Faradic psuedocapacitance materials and hydrogel material.

16. The method of manufacturing an electrochemical cell as in claim 10, wherein the electrodes comprise high surface area active material, Faradic psuedocapacitance materials and hydrogel material.

17. The method of manufacturing an electrochemical cell as in claim 8, wherein the capacitor comprises an asymmetrical capacitor.

18. The method of manufacturing an electrochemical cell as in claim 17, wherein the electrodes are different.

19. The method of manufacturing an electrochemical cell as in claim 17, wherein the electrodes comprise different amounts of high surface area active material, further wherein electrolyte is provided.

20. The method of manufacturing an electrochemical cell as in claim 17, wherein the electrodes comprise different amounts of Faradic psuedocapacitance materials, further wherein electrolyte is provided.

21. The method of manufacturing an electrochemical cell as in claim 17, wherein one electrode comprises high surface area active material and the other electrode comprises Faradic psuedocapacitance materials, further wherein electrolyte is provided.

22. The method of manufacturing an electrochemical cell as in claim 17, wherein the electrodes comprise different amounts of high surface area active material and hydrogel material, the hydrogel material comprising electrolyte therein.

23. The method of manufacturing an electrochemical cell as in claim 17, wherein the electrodes comprise different amounts of Faradic psuedocapacitance materials and hydrogel material.

24. The method of manufacturing an electrochemical cell as in claim 17, wherein one electrode comprises high surface area active material and hydrogel material, and the other electrode comprises Faradic psuedocapacitance materials and hydrogel material. kerfs

25. The method of manufacturing an electrochemical cell as in claim 1, wherein at least one kerf is provided along a slice pattern, wherein the kerf is filled with a removable substance, further wherein slicing is performed at a temperature range above a characteristic melting range of the removable substance.

26. The method of manufacturing an electrochemical cell as in claim 25, wherein a portion of a current collector associated with at least one of the electrodes are in a region where the kerf is located, further wherein slicing the laminar sheet through both opposing major surfaces into a desired size leaves the portion of the current collector exposed and substantially in condition for electrical connection.

27. The method of manufacturing an electrochemical cell as in claim 25, wherein removable substance is provided as each layer is formed.

28. The method of manufacturing an electrochemical cell as in claim 27, wherein each layer of removable substance is bonded to a preceding layer.

29. The method of manufacturing an electrochemical cell as in claim 25, wherein removable substance is provided as a set of layers is formed.

30. The method of manufacturing an electrochemical cell as in claim 25, wherein removable substance is provided after layers have been formed.

31. The method of manufacturing an electrochemical cell as in claim 1, wherein at least one kerf is provided along a slice pattern, wherein the kerf is filled with a housing material to be used for at least a portion of a cell stack housing.

32. The method of manufacturing an electrochemical cell as in claim 31, wherein housing material is provided as each layer is formed.

33. The method of manufacturing an electrochemical cell as in claim 31, wherein each layer of housing material is bonded to a preceding layer.

34. The method of manufacturing an electrochemical cell as in claim 31, wherein housing material is provided as a set of layers is formed.

35. The method of manufacturing an electrochemical cell as in claim 31, wherein housing material is provided after layers have been formed.

36. The method of manufacturing an electrochemical cell as in claim 1, wherein at least one kerf is provided along a slice pattern, wherein the kerf is filled with a conductor material to be used for connecting at least a portion of cell components in the laminar structure.

37. The method of manufacturing an electrochemical cell as in claim 36, wherein conductor material is provided as each layer is formed.

38. The method of manufacturing an electrochemical cell as in claim 36, wherein each layer of conductor material is bonded to a preceding layer.

39. The method of manufacturing an electrochemical cell as in claim 36, wherein conductor material is provided as a set of layers is formed.

40. The method of manufacturing an electrochemical cell as in claim 36, wherein conductor material is provided after layers have been formed.

41. The method of manufacturing electrochemical cells as in claim 1, wherein at least one of the electrochemical cells comprises a flow-through capacitor.

42. The method of manufacturing an electrochemical cell as in claim 41, wherein the capacitor comprises a symmetrical capacitor.

43. The method of manufacturing an electrochemical cell as in claim 42, wherein the electrodes are identical or substantially identical.

44. The method of manufacturing an electrochemical cell as in claim 42, wherein the electrodes comprise high surface area active material.

45. The method of manufacturing an electrochemical cell as in claim 42, wherein the electrodes comprise high surface area active material and hydrogel material.

46. The method of manufacturing an electrochemical cell as in claim 41, wherein the capacitor comprises an asymmetrical capacitor.

47. The method of manufacturing an electrochemical cell as in claim 46, wherein the electrodes are different in size or type.

48. The method of manufacturing an electrochemical cell as in claim 46, wherein the electrodes comprise high surface area active material of different quantities.

49. The method of manufacturing an electrochemical cell as in claim 46, wherein the electrodes comprise high surface area active material of different quantities and hydrogel material.

50. The method of manufacturing electrochemical cells as in claim 1, wherein the desired capacity is defined by the desired area of one of the surfaces of the planar sheet of each electrochemical cell.

51. The method of manufacturing electrochemical cells as in claim 1, further wherein kerf regions are provided at the locations on the laminar sheet corresponding to the position where slicing is to occur, further wherein the kerfs define a pattern of cutting of the laminar sheet.

52. The method of manufacturing an electrochemical cell as in claim 1, wherein at least one kerf is provided along a slice pattern, wherein the kerf is filled with a removable substance, a conductor path is formed in the removable substance, and conductor material is introduced in the conductor path to be used for connecting at least a portion of cell components in the laminar structure.

53. The method of manufacturing an electrochemical cell as in claim 1, wherein at least one kerf is provided along a slice pattern, wherein the kerf is filled with a housing material for use as at least a portion of a cell stack housing, a conductor path is formed in the housing material, and conductor material is introduced in the conductor path to be used for connecting at least a portion of cell components in the laminar structure.

54. A method of manufacturing an electrochemical cell comprising:

forming a first electrode layer in a laminar sheet;

forming a separator layer in a laminar sheet on the first electrode layer;

forming a second electrode layer in a laminar sheet on the separator;

forming a fluid flow layer adjacent the first electrode layer or the second electrode layer, wherein fluid flow openings are filled with a removable material during processing; and

slicing the stack of laminar sheets into a desired size with the removable substance therein.