Method of Integrating Electrochemical Devices Into and Onto Fixtures

• US 20100294428A1
• Filed: 05/20/2010
• Published: 11/25/2010
• Est. Priority Date: 05/20/2009
• Status: Abandoned Application

• Current Assignee: Sapurast Research LLC
• Original Assignee: Sapurast Research LLC
• Inventors: Than, John T., SNYDER, Shawn W., Brantner, Paul C., Neudecker, Bernd J., Keating, Joseph A.
• Application Number:
  US12/784,287
• Publication Number:
  US 20100294428A1
• Time in Patent Office: Days
• US Class Current: 156/321
• CPC Class Codes: H01M 10/0481 Compression means other than compression means for stacks of electrodes and separators
• CPC Class Codes: H01M 10/425 Structural combination with electronic components, e.g. electronic circuits integrated to the outside of the casing printed circuits H05K1/00
• CPC Class Codes: H01M 10/44 Methods for charging or discharging circuits for charging H02J7/00
• CPC Class Codes: H01M 50/213 adapted for cells having curved cross-section, e.g. round or elliptic H01M50/209, H01M50/216 take precedence
• CPC Class Codes: H01M 50/216 adapted for button or coin cells
• CPC Class Codes: H01M 50/244 Secondary casings; Racks; Suspension devices; Carrying devices; Holders characterised by their mounting method
• 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

Methods of integrating an electrochemical device to a fixture are disclosed. When performed, these methods may, for example, result in the improved performance and/or extended shelf life of the electrochemical device. These methods may include, for example, discharging an electrochemical device prior to an integration process, limiting the temperature exposure of the electrochemical device during the integration process, and/or applying a constraining force to a surface of the electrochemical device during an integration process.

Claims

1. A method of integrating an electrochemical device with a fixture comprising:

providing an electrochemical device comprising a negative electrode, an electrolyte, and a positive cathode, said positive cathode having a charge state that is less than the upper stability limit of the charge state of said positive cathode at room temperature;

providing a fixture;

heating said fixture and said electrochemical device at a temperature for a time period; and

affixing said electrochemical device to said fixture.

2. The method of claim 1, wherein said temperature comprises above about 70°

C.

3. The method of claim 1, wherein said temperature comprises above about 150°

C.

4. The method of claim 1, wherein said temperature comprises solder reflow processing temperatures.

5. The method of claim 4, wherein said temperature comprises above about 260°

C.

6. The method of claim 1, wherein said electrochemical device comprises lithium.

7. The method of claim 6, wherein said positive cathode comprises lithium.

8. The method of claim 7, wherein said positive cathode comprises LiCoO₂.

9. The method of claim 8, wherein said upper stability limit comprises about 4.2V measured against said negative electrode.

10. The method of claim 9, wherein said negative electrode comprises a virtual lithium reference electrode.

11. The method of claim 9, wherein said negative electrode comprises a metallic lithium anode.

12. The method of claim 9, wherein said temperature comprises up to about 160°

C. and said time period comprises about one hour.

13. The method of claim 10, wherein said temperature comprises up to about 160°

C. and said time period comprises about one hour.

14. The method of claim 11, wherein said temperature comprises up to about 160°

C. and said time period comprises about one hour.

15. The method of claim 8, wherein said upper stability limit comprises about 4.1V measured against said negative electrode.

16. The method of claim 15, wherein said negative electrode comprises a virtual lithium reference electrode.

17. The method of claim 15, wherein said negative electrode comprises a metallic lithium anode.

18. The method of claim 15, wherein said temperature comprises up to about 200°

C. and said time period comprises about one hour.

19. The method of claim 16, wherein said temperature comprises up to about 200°

C. and said time period comprises about one hour.

20. The method of claim 17, wherein said temperature comprises up to about 200°

C. and said time period comprises about one hour.

21. The method of claim 8, wherein said upper stability limit comprises about 4.05V measured against said negative electrode.

22. The method of claim 21, wherein said negative electrode comprises a virtual lithium reference electrode.

23. The method of claim 21, wherein said negative electrode comprises a metallic lithium anode.

24. The method of claim 21, wherein said temperature comprises up to about 230°

C. and said time period comprises up to about one hour.

25. The method of claim 22, wherein said temperature comprises up to about 230°

C. and said time period comprises up to about one hour.

26. The method of claim 23, wherein said temperature comprises up to about 230°

C. and said time period comprises up to about one hour.

27. The method of claim 8, wherein said upper stability limit comprises about 4.0V measured against said negative electrode.

28. The method of claim 27, wherein said negative electrode comprises a virtual lithium reference electrode.

29. The method of claim 27, wherein said negative electrode comprises a metallic lithium anode.

30. The method of claim 27, wherein said temperature comprises up to about 250°

C. and said time period comprises up to about one hour.

31. The method of claim 28, wherein said temperature comprises up to about 250°

C. and said time period comprises up to about one hour.

32. The method of claim 29, wherein said temperature comprises up to about 250°

C. and said time period comprises up to about one hour.

33. The method of claim 8, wherein said upper stability limit comprises about 3.95V measured against said negative electrode.

34. The method of claim 33, wherein said negative electrode comprises a virtual lithium reference electrode.

35. The method of claim 33, wherein said negative electrode comprises a metallic lithium anode.

36. The method of claim 33, wherein said temperature comprises up to about 270°

C. and said time period comprises up to about one hour.

37. The method of claim 34, wherein said temperature comprises up to about 270°

C. and said time period comprises up to about one hour.

38. The method of claim 35, wherein said temperature comprises up to about 270°

C. and said time period comprises up to about one hour.

39. The method of claim 1, wherein said heating further comprises applying said temperature uniformly to at least one major surface of said electrochemical device.

40. The method of claim 1, further comprising:

fixating said electrochemical device in a manner that substantially prevents mechanical distortion of said electrochemical device.

41. The method of claim 1, further comprising:

compressing said electrochemical device in a manner that substantially prevents mechanical distortion of said electrochemical device.

42. The method of claim 41, wherein said compressing further comprises applying hydraulic pressure.

43. The method of claim 1, wherein said fixture comprises an item selected from the group of:

printed circuit board, flexible printed circuit board, chip, multi-layer printed circuit board, multi-layer flexible printed circuit board, smart card, credit card, polymeric laminate, non-polymeric laminate, cast, injection mold, silicon wafer, silicon wafer sandwich, silicon wafer laminate, ceramic holder, metallic holder.

44. A method of integrating an electrochemical device with a fixture comprising:

providing an electrochemical device, said electrochemical device having not been previously charged;

providing a fixture;

heating said fixture and said electrochemical device at a temperature for a time period; and

affixing said electrochemical device to said fixture.