METHOD OF MAKING A CORRUGATED ELECTRODE CORE TERMINAL INTERFACE

• US 20080235944A1
• Filed: 03/31/2007
• Published: 10/02/2008
• Est. Priority Date: 03/31/2007
• Status: Abandoned Application

• Current Assignee: Tesla Inc.
• Original Assignee: Tesla Inc.
• Inventors: Miller, John
• Application Number:
  US11/694,995
• Publication Number:
  US 20080235944A1
• Time in Patent Office: Days
• US Class Current: 29/857
• CPC Class Codes: H01G 11/22 Electrodes
• CPC Class Codes: H01G 11/74 Terminals, e.g. extensions of current collectors
• CPC Class Codes: H01G 11/84 Processes for the manufacture of hybrid or EDL capacitors, or components thereof
• CPC Class Codes: H01R 4/14 by wrapping
• CPC Class Codes: H01R 4/20 using a crimping sleeve H01R4/01 takes precedence
• CPC Class Codes: H01R 43/033 for wrapping or unwrapping wire connections
• CPC Class Codes: H01R 43/04 for forming connections by deformation, e.g. crimping tool
• CPC Class Codes: Y02E 60/13 Energy storage using capacitors
• CPC Class Codes: Y10T 29/49174 Assembling terminal to elongated conductor
• CPC Class Codes: Y10T 29/49195 with end-to-end orienting
• CPC Class Codes: Y10T 29/49218 with deforming
• CPC Class Codes: Y10T 29/53217 Means to simultaneously assemble multiple, independent conductors to terminal

Abstract

A method of making a corrugated electrode core terminal interface is disclosed.

Claims

1. A method of making a corrugated electrode core terminal interface, comprising:

(a.) spacing a plurality of termination wires along fold areas of a current collector foil;

(b.) wrapping the plurality of termination wires within the current collector foil;

(c.) folding the current collector foil along collector foil fold lines;

(d.) collecting the plurality of termination wires, whereby at least two groups of termination wires are thereby bundled together;

(e.) inserting the at least two groups of bundled termination wires into at least two barrel termination leads, and;

(f.) crimping the barrel termination leads.

2. A means for making a corrugated electrode core terminal interface, comprising:

(a.) means for spacing a plurality of termination wires along fold areas of a current collector foil;

(b .) means for wrapping the plurality of termination wires within the current collector foil;

(c.) means for folding the current collector foil along collector foil fold lines;

(d.) means for collecting the plurality of termination wires, whereby at least two groups of termination wires are thereby bundled together;

(e.) means for inserting the plurality of termination wires into at least one barrel termination, and;

(f.) means for crimping the barrel termination leads.

3. A method of making a corrugated electrode core terminal interface, comprising:

(a.) spacing a plurality of termination wires along fold areas of a first current collector foil;

(b.) operatively connecting each one of the plurality of termination wires to the first current collector foil member;

(c.) folding the first current collector foil along collector foil fold lines;

(d.) collecting the plurality of termination wires, and

(e.) forming the plurality of termination wires into at least one connector.

4. The method of claim 3 wherein the plurality of termination wires are spaced at equal intervals along the at least one current collector foil.

5. The method of claim 3 wherein the operatively connecting each one of the plurality of termination wires to the first current collector foil member comprises wrapping the termination wires within the first current collector foil.

6. The method of claim 5 wherein the termination wires are wrapped within the first current collector foil at the collector foil fold lines.

7. The method of claim 3 wherein the operatively connecting each one of the plurality of termination wires to the first current collector foil member comprises ultrasonically welding the termination wires to the first current collector foil.

8. The method of claim 3 wherein there is no overhang with respect to either the first current collector foil member, a separator element, or a second current collector foil member.

9. The method of claim 3 wherein the operation of collecting the plurality of termination wires comprises bundling together the plurality of termination wires into at least two groups of termination wires.

10. The method of claim 3 wherein the first current collector foil member comprises an activated element.

11. The method of claim 3 further comprising affixing the wires to leads.

12. The method of claim 11 wherein the affixing is by crimping.

13. The method of claim 3 wherein the connector is a barrel connector.

14. A corrugated electrode core terminal interface made by the method of claim 3.

15. An electric energy device comprising the corrugated electrode core terminal interface of claim 14.

16. An electric energy device of claim 15 selected from the group consisting of an ultracapacitor and a lithium ion battery.