CID retention device for Li-ion cell

• US 20090029193A1
• Filed: 06/19/2008
• Published: 01/29/2009
• Est. Priority Date: 06/22/2007
• Status: Active Grant

• Current Assignee: Boston-Power Inc.
• Original Assignee: Boston-Power Inc.
• Inventors: Elia, Mimmo, Linna, Jan-Roger B., Onnerud, Per, Partin, Phillip E., Chamberlain, Richard V. II
• Granted Patent: US 7,838,143 B2
• Time in Patent Office: Days
• US Class Current: 429/7
• CPC Class Codes: H01M 10/0525 Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodes; Lithium-ion batteries
• CPC Class Codes: H01M 50/103 prismatic or rectangular H01M50/109, H01M50/11 take precedence
• CPC Class Codes: H01M 50/107 having curved cross-section, e.g. round or elliptic H01M50/103, H01M50/109, H01M50/11 take precedence
• CPC Class Codes: H01M 50/342 Non-re-sealable arrangements
• CPC Class Codes: H01M 50/574 Devices or arrangements for the interruption of current
• CPC Class Codes: H01M 50/578 in response to pressure
• CPC Class Codes: H01M 50/586 inside the batteries, e.g. incorrect connections of electrodes
• CPC Class Codes: H01M 50/593 Spacers; Insulating plates
• 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
• CPC Class Codes: Y10T 29/49108 Electric battery cell making

Abstract

A low pressure current interrupt device (CID) activates at a minimal threshold internal gauge pressure in a range of, for example, between about 4 kg/cm² and about 9 kg/cm². Preferably, the CID includes a first conductive plate and a second conductive plate in electrical communication with the first conductive plate, the electrical communication between the first and the second conductive plates being interrupted at the minimal threshold internal gauge pressure. More preferably, the first conductive plate includes a frustum having a first end and a second end, a base extending radially from a perimeter of the first end of the frustum, and an essentially planar cap sealing the second end of the frustum. The first end has a broader diameter than the second end. More preferably, the second conductive plate is in electrical contact with the essentially planar cap through a weld. A battery, preferably a lithium-ion battery, comprises a CID as described above. A method of manufacturing such a CID comprises forming first and second conductive plates as described above, and welding the second conductive plate onto the first conductive plate while a temperature of the first conductive plate is controlled so as not to exceed the melting point of a surface of the first conductive plate opposite the weld.

Claims

1. A current interrupt device, comprising:

a) a first conductive plate, including;

i) a frustum having a first end, a second end, the first end having a broader diameter than the second end,

ii) a base extending radially from a perimeter of the first end of the frustum, and

iii) an essentially planar cap sealing the second end of the frustum;

b) a second conductive plate in electrical contact with the essentially planar cap of the first conductive plate.

2. The current interrupt device of claim 1, wherein the second conductive plate is in electrical contact with the essentially planar cap of the first conductive plate through a weld.

3. The current interrupt device of claim 2, wherein the weld connecting the first and second plates ruptures when a gauge pressure between the plates is in a range of between about 4 kg/cm² and about 9 kg/cm².

4. The current interrupt device of claim 2, wherein the weld ruptures when a gauge pressure between the plates is in a range of between about 7 kg/cm² and about 9 kg/cm².

5. The current interrupt device of claim 2, wherein the second conductive plate defines a depression, and wherein the weld is at the depression.

6. The current interrupt device of claim 5, wherein the weld is at least one spot weld.

7. The current interrupt device of claim 6, wherein at least one of the spot welds includes aluminum.

8. The current interrupt device of claim 6, wherein the weld is two spot welds.

9. The current interrupt device of claim 1, wherein the second conductive plate defines at least one opening.

10. The current interrupt device of claim 2, wherein at least one of the first and second conductive plates include aluminum.

11. The current interrupt device of claim 10, wherein the first and second conductive plates both include aluminum.

12. The current interrupt device of claim 11, wherein the thickness of the cap is in a range of between about 0.05 millimeter and about 0.5 millimeter

13. The current interrupt device of claim 12, wherein the thickness of the cap is about 0.127 millimeter.

14. The current interrupt device of claim 12, wherein the diameter of the cap is in a range of between about 2 millimeter and about 8 millimeter.

15. The current interrupt device of claim 14, wherein a height of the cap from the base is in a range of between about 0.5 millimeter and about 1 millimeter.

16. The current interrupt device of claim 15, wherein the height of the cap from the base is about 0.762 millimeter.

17. The current interrupt device of claim 15, wherein the frustum has an angle to a plane parallel to the base of the first conductive plate in a range of between about 15 degrees and about 25 degrees.

18. The current interrupt device of claim 1, further including an electrically insulating ring that extends about the perimeter of the frustum and between the base of the first conductive plate and the second conductive plate.

19. The current interrupt device of claim 18, wherein the base of the first conductive plate includes at least one tab and wherein the electrically insulating ring defines at least one opening, the tab and the opening being capable of alignment when the insulating ring and the base are concentric, and wherein the tab can be maleably adjusted to secure the insulating ring to the first conductive plate.

20. The current interrupt device of claim 19, wherein the electrically insulating ring defines a groove about a perimeter of the insulating ring, and further including a metal ring having tabs, whereby the metal ring can rest inside the groove and whereby the tabs can be maleably adjusted and secured to a metal surface on which the first conductive plate is resting, thereby securing the insulating ring over the first conductive plate.

21. The current interrupt device of claim 1, wherein the thickness of the second conductive plate proximate to the weld with the first conductive plate is equal or greater than one-half of the thickness of the first conductive plate proximate to the weld, but less than the thickness of the first conductive plate proximate to the weld.

22. A battery, comprising:

a) a first terminal in electrical communication with a first electrode of the battery;

b) a second terminal in electrical communication with a second electrode of the battery;

c) a battery can having a cell casing and a lid which are in electrical communication with each other, the battery can being electrically insulated from the first terminal, wherein at least a portion of the battery can is at least a component of the second terminal, or is electrically connected to the second terminal; and

d) at least one current interrupt device in electrical communication with either of the first and second electrodes, the current interrupt device including;

i) a first conductive plate that includes a frustum, the frustum including a first end and a second end having a diameter less than that of the first end, and an essentially planar cap sealing the second end of the frustum, wherein the base is proximal to the battery can, and the essentially planar cap is distal to the battery can; and

ii) a second conductive plate in electrical communication with the first conductive plate and with either of the first and second electrodes.

23. The battery of claim 22, wherein the first conductive plate and the second conductive plate are bonded together by at least one weld, and wherein the second conductive plate defines at least one opening.

24. The battery of claim 23, wherein the cell casing is a prismatic cell casing.

25. The battery of claim 24, wherein the second conductive plate defines a depression, and wherein the weld is at the depression.

26. The battery of claim 25, wherein the weld is at least one spot weld.

27. The battery of claim 26, wherein at least one of the spot welds includes aluminum.

28. The battery of claim 26, wherein the weld is two spot welds.

29. The battery of claim 22, wherein at least one of the first and second and second conductive plates include aluminum.

30. The battery of claim 29, wherein the first and second conductive plates both include aluminum.

31. The battery of claim 30, wherein the thickness of the cap is in a range of between about 0.05 millimeter and about 0.5 millimeter.

32. The battery of claim 31, wherein the diameter of the cap is in a range of between about 2 millimeter and about 8 millimeter.

33. The battery of claim 32, wherein the height of the cap from the base is in a range of between about 0.5 millimeter and about 1 millimeter.

34. The battery of claim 33, wherein the frustum has an angle to a plane parallel to the base of the first conductive plate in a range of between about 15 degrees and about 25 degrees.

35. The battery of claim 22, further including an electrically insulating ring that extends about the perimeter of the frustum and between the base of the first conductive plate and the second conductive plate.

36. The battery of claim 35, wherein the base of the first conductive plate includes at least one tab and when the electrically insulating ring defines at least one opening, the tab and the opening being capable of alignment when the insulating ring and the base are concentric, and wherein the tab can be malleably adjusted to secure the insulating ring to the first conductive plate.

37. The battery of claim 35, wherein the electrically insulating ring defines a groove about a perimeter of the insulating ring, and further including a metal ring having tabs, whereby the metal ring can rest inside the groove and whereby the tabs can be malleably adjusted and secured to a metal surface on which the first conductive plate is resting, thereby securing the insulating ring over the first conductive plate.

38. The battery of claim 22, wherein the weld connecting the first and second plates ruptures when a gauge pressure between the plates is in a range of between about 4 kg/cm² and about 9 kg/cm².

39. The battery of claim 38, wherein the weld ruptures at a gauge pressure in a range of between about 5 kg/cm² and about 9 kg/cm².

40. The battery of claim 39, wherein the weld ruptures at a gauge pressure in a range of between about 7 kg/cm² and about 9 kg/cm².

41. The battery of claim 22, wherein the thickness of the second conductive plate proximate to the weld with the first conductive plate is equal or greater than one-half of the thickness of the first conductive plate proximate to the weld, but less than the thickness of the first conductive plate proximate to the weld.

42. The battery of claim 22, wherein the current interrupt device is in electrical communication with the battery can.

43. The battery of claim 42, wherein the current interrupt device is in electrical communication with the lid of the battery can, and the lid includes a recess facing toward the first conductive plate.

44. The battery of claim 43, wherein the recess is co-terminus with the perimeter of the first end of the frustum.

45. The battery of claim 22, wherein the first electrode includes an active cathode material, the active cathode material including a mixture that includes:

a) a lithium cobaltate; and

b) a manganate spinel represented by an empirical formula of

Li_(1+x1)(Mn<sub>1−

y1</sub>A′

_y2)<sub>2−

x2</sub>O_z1

wherein;

x1 and x2 are each independently equal to or greater than 0.01 and equal to or less than 0.3;

y1 and y2 are each independently equal to or greater than 0.0 and equal to or less than 0.3;

z1 is equal to or greater than 3.9 and equal to or less than 4.2; and

A′

is at least one member of the group consisting of magnesium, aluminum, cobalt, nickel and chromium,

wherein the lithium cobaltate and the manganate spinel are in a weight ratio of lithium cobaltate;

manganate spinel between about 0.95;

0.05 and about 0.6;

0.4.

46. The battery of claim 22, wherein the first electrode includes an active cathode material including a lithium cobaltate.

47. The battery of claim 46, wherein the lithium cobaltate is represented by an empirical formula of Li_1+x8CoO₈, wherein x8 is equal to or greater than zero and equal to or less than 0.2, and z8 is equal to or greater than 1.9 and equal to or greater than 2.1.

48. The battery of claim 47, wherein the active cathode material includes a mixture that includes:

a) Li_1+x8CoO_z8; and

b) Li_(1+x1)Mn₂O_z1 wherein;

x1 is equal to or greater than 0.01 and equal to or less than 0.3; and

z1 is equal to or greater than 3.9 and equal to or less than 4.2,

wherein Li_1+x8CoO_z8 and Li_(1+x1)Mn₂O_z1 are in a weight ratio of lithium cobaltate;

manganate spinel between about 0.95;

0.05 and about 0.6;

0.4.

49. The battery of claim 22, wherein the first electrode includes an active cathode material, the active cathode material including at least one lithium oxide selected from the group consisting of:

a) a lithium cobaltate;

b) a lithium nickelate;

c) a manganate spinel represented by an empirical formula of

Li_(1+x1)(Mn<sub>1−

y1</sub>A′

_y2)<sub>2−

x2</sub>O_z1

wherein;

x1 and x2 are each independently equal to or greater than 0.01 and equal to or less than 0.3;

y1 and y2 are each independently equal to or greater than 0.0 and equal to or less than 0.3;

z1 is equal to or greater than 3.9 and equal to or less than 4.2; and

A′

is at least one member of the group consisting of magnesium, aluminum, cobalt, nickel and chromium;

d) a manganate spinel represented by an empirical formula of

Li_(1+x1)Mn₂O_z1

wherein;

x1 is equal to or greater than 0.01 and equal to or less than 0.3; and

z1 is equal to or greater than 3.9 and equal to or less than 4.2; and

e) and an olivine compound represented by an empirical formula of

Li<sub>(1−

x10)</sub>A″

_x10MPO₄

wherein;

x10 is equal to or greater than 0.05 and equal to or less than 0.2, or x10 is equal to or greater than 0.0 and equal to or less than 0.1; and

M is at least one member of the group consisting of iron, manganese, cobalt and magnesium; and

A″

is at least one member of the group consisting of sodium, magnesium, calcium, potassium, nickel and niobium.

50. A battery, comprising:

a) a first terminal in electrical communication with a first electrode of the battery;

b) a second terminal in electrical communication with a second electrode of the battery;

c) a battery can having a cell casing and a lid welded on the cell casing, the battery can being electrically insulated from the first terminal, wherein at least a portion of the battery can is at least a component of the second terminal, or is electrically connected to the second terminal, wherein the welded lid is detached when an internal gauge pressure is equal to, or greater than, about 20 kg/cm²;

d) at least one current interrupt device in electrical communication with either of the first and second electrodes, the current interrupt device including;

i) a first conductive plate that includes a frustum, the frustum including a first end and a second end having a diameter less than that of the first end, and an essentially planar cap sealing the second end of the frustum, wherein the base is proximal to the battery can and the essentially planar cap is distal to the battery can; and

ii) a second conductive plate in electrical communication with the first conductive plate and with either of the first and second electrodes,

wherein the weld connecting the first and second plates ruptures when a gauge pressure between the plates is in a range of between about 4 kg/cm² and 9 kg/cm²; and

e) at least one venting means on the cell casing, through which gaseous species inside of the battery exit when an internal gauge pressure is in a range of between about 10 kg/cm² and about 20 kg/cm².

51. The battery of claim 50, wherein the cell casing is a prismatic cell casing.

52. The battery of claim 51, wherein the cell casing has a 183665 configuration.

53. A lithium-ion battery, comprising:

a) a battery can that includes a cell casing and a lid that are in electrical communication with each other; and

b) a current interrupt device that includes a first conductive plate and a second conductive plate in electrical communication with each other, the first conductive plate is in electrical communication with the battery can,

wherein the electrical communication between the first and second conductive plates is interrupted when a gauge pressure between the plates is in a range of between about 4 kg/cm² and about 9 kg/cm².

54. The lithium-ion battery of claim 53, wherein an internal gauge pressure of the battery under a normal working condition is less than about 2 kg/cm².

55. The lithium-ion battery of claim 53, wherein the first conductive plate is in electrical contact with the lid of the battery can.

56. The lithium-ion battery of claim 53, comprising a cathode that includes an active cathode material, the active cathode material including a mixture that includes:

a) a lithium cobaltate; and

b) a manganate spinel represented by an empirical formula of

Li_(1+x1)(Mn<sub>1−

y1</sub>A′

_y2)<sub>2−

x2</sub>O_z1

wherein;

x1 and x2 are each independently equal to or greater than 0.01 and equal to or less than 0.3;

y1 and y2 are each independently equal to or greater than 0.0 and equal to or less than 0.3;

z1 is equal to or greater than 3.9 and equal to or less than 4.2; and

A′

is at least one member of the group consisting of magnesium, aluminum, cobalt, nickel and chromium,

wherein the lithium cobaltate and the manganate spinel are in a weight ratio of lithium cobaltate;

manganate spinel between about 0.95;

0.05 and about 0.9;

0.1 to about 0.6;

0.4.

57. The lithium-ion battery of claim 53, comprising a cathode that includes an active cathode material including a lithium cobaltate.

58. The lithium-ion battery of claim 57, wherein the lithium cobaltate is represented by an empirical formula of L_1+x8CoO_z8, wherein x8 is equal to or greater than zero and equal to or less than 0.2 and z8 is equal to or greater than 1.9 and equal to or greater than 2.1.

59. The lithium-ion battery of claim 58, wherein the active cathode material includes a mixture that includes:

a) Li_1+x8CoO_z8; and

b) Li_(1+x1)Mn₂O_z1 wherein;

x1 is equal to or greater than 0.01 and equal to or less than 0.3; and

z1 is equal to or greater than 3.9 and equal to or less than 4.2,

wherein Li_1+x8CoO₈ and Li_(1+x1)Mn₂O_z1 are in a weight ratio of lithium cobaltate;

manganate spinel between about 0.95;

0.05 and about 0.6;

0.4.

60. The lithium-ion battery of claim 53, wherein the first electrode is a cathode that includes an active cathode material, the active cathode material including at least one lithium oxide selected from the group consisting of:

a) a lithium cobaltate;

b) a lithium nickelate;

c) a manganate spinel represented by an empirical formula of

Li_(1+x1)(Mn<sub>1−

y1</sub>A′

_y2)<sub>2−

x2</sub>O_z1

wherein;

x1 and x2 are each independently equal to or greater than 0.01 and equal to or less than 0.3;

y1 and y2 are each independently equal to or greater than 0.0 and equal to or less than 0.3;

z1 is equal to or greater than 3.9 and equal to or less than 4.2; and

A′

is at least one member of the group consisting of magnesium, aluminum, cobalt, nickel and chromium;

d) a manganate spinel represented by an empirical formula of

Li_(1+x1)Mn₂O_z1

wherein;

x1 is equal to or greater than 0.01 and equal to or less than 0.3; and

z1 is equal to or greater than 3.9 and equal to or less than 4.2; and

e) and an olivine compound represented by an empirical formula of

Li<sub>(1−

x10)</sub>A″

_x10MPO₄

wherein;

x10 is equal to or greater than 0.05 and equal to or less than

0.2, or x10 is equal to or greater than 0.0 and equal to or less than 0.1; and

M is at least one member of the group consisting of iron, manganese, cobalt and magnesium; and

A″

is at least one member of the group consisting of sodium, magnesium, calcium, potassium, nickel and niobium.

61. A lithium-ion battery, comprising:

a) a first terminal in electrical communication with a first electrode of the battery;

b) a second terminal in electrical communication with a second electrode of the battery;

c) a battery can having a cell casing and a lid welded on the cell casing, the battery can being electrically insulated from the first terminal, wherein at least a portion of the battery can is at least a component of the second terminal, or is electrically connected to the second terminal, wherein the welded lid is detached from the cell casing when an internal gauge pressure is equal to, or greater than, about 20 kg/cm²;

d) at least one current interrupt device in electrical communication with either of the first and second electrodes, the current interrupt device including a first conductive plate and a second conductive plate in electrical communication with each other, wherein the first conductive plate of the current interrupt device is in electrical communication with the cell can, and wherein the electrical communication between the first and second conductive plates is interrupted when an internal gauge pressure is in a range of between about 4 kg/cm² and about 9 kg/cm²; and

e) at least one venting means on the cell casing, through which gaseous species inside of the battery exit when an internal gauge pressure is in a range of between about 10 kg/cm² and about 20 kg/cm².

62. The battery of claim 61, wherein the cell casing is a prismatic cell casing.

63. The battery of claim 62, wherein the cell casing has a 183665 configuration.

64. A method of manufacturing a current interrupt device, comprising the steps of

a) forming a first conductive plate, including:

i) a frustum having a first end and a second end having a diameter less than that of the first end;

ii) a base extending radially from a perimeter of the first end of the frustum; and

iii) an essentially planar cap sealing the second end of the frustum;

b) forming a second conductive plate; and

c) welding the second conductive plate onto the essentially planar cap of the first conductive plate while a temperature of the first conductive plate is controlled so as not to exceed the melting point of a surface of the first conductive plate opposite the weld.

65. The method of Clam 64, wherein the welding is performed using a laser.

66. The method of claim 65, the welding is performed on at least one spot.

67. The method of claim 66, wherein the welding is performed on two spots.

68. A method of manufacturing a battery, comprising the steps of:

a) forming a current interrupt device, including the steps of;

i) forming a first conductive plate that includes a frustum, having a first end and a second end having a diameter less than that that of the first end, a base extending radially from a perimeter of the first end of the frustum, and an essentially planar cap sealing the second end of the frustum;

ii) forming a second conductive plate;

iii) welding the second conductive plate onto the essentially planar cap of the first conductive plate while a temperature of the first conductive plate is controlled so as not to exceed the melting point of a surface of the first conductive plate opposite the weld, thereby forming the current interrupt device;

b) attaching either a first electrode or a second electrode of the battery to the current interrupt device;

c) attaching the current interrupt device onto a battery can of the battery, the battery can including a cell casing and a lid which are in electrical communication with each other; and

d) forming a first terminal in electrical communication with the first electrode, and a second terminal in electrical communication with the second electrode.

69. The method of claim 68, wherein the current interrupt device is welded onto the lid of the battery can.

70. The method of claim 69, wherein the welding of the current interrupt device onto the lid of the battery can is performed by seam welding a circumferential interface between the lid and the first conductive plate of the current interrupt device.

71. The method of claim 70, wherein the welding of the current interrupt device onto the lid of the battery can is performed by penetration welding at the base of the first conductive plate.

72. The method of claim 69, further including the step of welding the lid of the battery can onto the cell casing of the battery can.

73. The method of claim 72, wherein the weld connecting the lid and the cell casing ruptures when a gauge pressure between the lid and the cell casing is greater than or equal to about 20 kg/cm².

74. The method of claim 68, wherein the weld connecting the second conductive plate and the essentially planar cap of the first conductive plate ruptures when a gauge pressure between the second conductive plate and the essentially planar cap is in a range of between about 4 kg/cm² and about 9 kg/cm².

75. The method of claim 68, further including the step of forming at least one venting means on the cell casing, wherein gaseous species inside the battery exit through the venting means when an internal gauge pressure is in a range of between about 10 kg/cm² and about 20 kg/cm².

76. A method of manufacturing a lithium-ion battery, comprising:

a) forming a battery can that includes a cell casing and a lid that are in electrical communication with each other;

b) forming a current interrupt device, including the steps of;

i) forming a first conductive plate

ii) forming a second conductive plate;

iii) welding the second conductive plate onto the first conductive plate while a temperature of the first conductive plate is controlled so as not to exceed the melting point of a surface of the first conductive plate opposite the weld, thereby forming the current interrupt device, wherein the weld connecting the first conductive plate and the second conductive plate ruptures when a gauge pressure between the first and second conductive plates is in a range of between about 4 kg/cm² and about 9 kg/cm²;

c) attaching either a first electrode or a second electrode of the battery to the second conductive plate of the current interrupt device;

d) attaching the first conductive plate of the current interrupt device to the battery can;

e) forming at least one venting means on the cell casing, through which gaseous species inside the battery exit when an internal gauge pressure of the battery is in a range of between about 10 kg/cm² and about 20 kg/cm²;

f) welding the lid of the battery can onto the cell casing, wherein the weld connecting the lid and battery can ruptures when a gauge pressure between the lid and the cell casing is equal to, or greater than, about 20 kg/cm²; and

g) forming a first terminal in electrical communication with the first electrode, and a second terminal in electrical communication with the second electrode.