ELECTRODES WITH RAISED PATTERNS

• US 20080248386A1
• Filed: 04/05/2007
• Published: 10/09/2008
• Est. Priority Date: 04/05/2007
• Status: Abandoned Application

• Current Assignee: 3M Innovative Properties Company (3M Company)
• Original Assignee: 3M Innovative Properties Company (3M Company)
• Inventors: Christensen, Leif, Obrovac, Mark N., Magnuson, Douglas C.
• Application Number:
  US11/696,979
• Publication Number:
  US 20080248386A1
• Time in Patent Office: Days
• US Class Current: 429/209
• CPC Class Codes: H01M 10/052 Li-accumulators
• CPC Class Codes: H01M 10/0587 of accumulators having only wound construction elements, i.e. wound positive electrodes, wound negative electrodes and wound separators
• CPC Class Codes: H01M 4/0404 by coating on electrode collectors
• CPC Class Codes: H01M 4/0435 Rolling or calendering
• CPC Class Codes: H01M 4/134 Electrodes based on metals, Si or alloys
• CPC Class Codes: H01M 4/1395 of electrodes based on metals, Si or alloys
• CPC Class Codes: H01M 4/70 characterised by shape or form
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y02P 70/50 Manufacturing or production processes characterised by the final manufactured product

Abstract

Provided is an electrode for an electrochemical cell that includes a current collector, and an active material in electrical contact with the current collector, wherein the electrode has a raised pattern as well as a method of making and using the same and also for electrochemical cells incorporating the same.

Claims

1. An electrode for an electrochemical cell comprising:

a current collector, and

an active material in electrical contact with the current collector,

wherein the electrode has a raised pattern.

2. The electrode of claim 1 wherein the current collector comprises a foil.

3. The electrode of claim 2 wherein the foil has a thickness of from about 5 microns to about 20 microns.

4. The electrode of claim 1 wherein the current collector is selected from aluminum, aluminum alloys, copper, stainless steel, nickel and combinations thereof.

5. The electrode of claim 1 wherein the electrode comprises a negative electrode.

6. The electrode of claim 1 wherein the active material comprises an alloy powder.

7. The electrode of claim 6 wherein the powder comprises graphite.

8. The electrode of claim 1 wherein the electrode comprises a positive electrode.

9. The electrode of claim 1 wherein the active material is provided as a thin film.

10. The electrode of claim 1 wherein the raised pattern comprises a corrugation or raised features or both.

11. The electrode of claim 1 comprising a raised pattern on at least one edge of the electrode.

12. The electrode of claim 1 wherein the raised pattern comprises concave and convex raised features.

13. The electrode of claim 1 wherein the pattern comprises a substantially sinusoidal cross-section.

14. The electrode of claim 1 wherein the pattern comprises a square-lattice or a triangular lattice.

15. The pattern of claim 14 further comprising raised dots.

16. A method of making an electrode comprising:

adding an active material to a current collector; and

providing the current collector that includes an active material with a raised pattern.

17. The method of claim 16 wherein adding an active material comprises applying a coating.

18. The method of claim 17 further comprising drying the coating.

19. The method of claim 16 wherein adding an active material comprises applying a thin film of material.

20. The method of claim 16 wherein providing the current collector with a raised pattern comprises passing the electrode through embossing rollers.

21. The method of claim 16 wherein providing the current collector with a raised pattern is performed at pressures from about 10 kPa to about 250 kPa.

22. The method of claim 16 further comprising calendering the current collector that includes an active material.

23. The method of claim 22 wherein calendering is done before embossing.

24. The method of claim 22 wherein calendering comprises passing the current collector that includes an active material between rollers at a pressure of from about 250 MPa to about 1500 MPa.

25. An electrochemical cell comprising:

a negative electrode,

a positive electrode, and

a separator,

wherein the negative electrode, the positive electrode, or both comprise;

a current collector, and an active material in electrical contact with the current collector,

wherein at least one of the electrodes that comprises an active material in electrical contact with the current collector has a raised pattern.

26. A battery pack comprising at least one cell according to claim 25.