POLYMER DIPPED POUCH CELL

• US 20200136106A1
• Filed: 10/24/2019
• Published: 04/30/2020
• Est. Priority Date: 10/24/2018
• Status: Active Grant

• Current Assignee: HHeLi, LLC
• Original Assignee: HHeLi, LLC
• Inventors: Johnson, Paige L., Fleetwood, II, James Dean
• Granted Patent: US 11,482,752 B2
• Time in Patent Office: Days
• CPC Class Codes: H01M 10/052 Li-accumulators
• CPC Class Codes: H01M 10/0585 of accumulators having only flat construction elements, i.e. flat positive electrodes, flat negative electrodes and flat separators
• CPC Class Codes: H01M 2004/027 Negative electrodes
• CPC Class Codes: H01M 2004/028 Positive electrodes
• CPC Class Codes: H01M 4/131 Electrodes based on mixed oxides or hydroxides, or on mixtures of oxides or hydroxides, e.g. LiCoOx
• CPC Class Codes: H01M 4/134 Electrodes based on metals, Si or alloys
• CPC Class Codes: H01M 4/382 Lithium H01M4/405 takes precedence
• CPC Class Codes: H01M 4/405 Alloys based on lithium
• CPC Class Codes: H01M 4/485 of mixed oxides or hydroxides for inserting or intercalating light metals, e.g. LiTi2O4 or LiTi2OxFy H01M4/505, H01M4/525 take precedence
• CPC Class Codes: H01M 4/661 Metal or alloys, e.g. alloy coatings H01M4/669 take precedence
• CPC Class Codes: H01M 50/116 characterised by the material
• CPC Class Codes: H01M 50/119 Metals
• CPC Class Codes: H01M 50/121 Organic material
• CPC Class Codes: H01M 50/124 having a layered structure
• CPC Class Codes: H01M 50/209 adapted for prismatic or rectangular cells H01M50/216 takes precedence
• CPC Class Codes: H01M 50/24 adapted for protecting batteries from their environment, e.g. from corrosion thermal insulation H01M10/658
• CPC Class Codes: H01M 50/417 Polyolefins
• CPC Class Codes: H01M 50/545 formed by the casing of the cells cup shaped terminals adapted for cells having curved cross-section H01M50/56
• CPC Class Codes: H01M 50/55 on the same side of the cell
• CPC Class Codes: H01M 50/553 Terminals adapted for prismatic, pouch or rectangular cells
• 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

A pouch cell includes a copper foil forming a pouch, an active material layer adjacent to the copper foil inside the pouch forming an anode with the copper, and a lithium-based cathode inside the pouch. The cell includes a separator interposing the one active material layer and the lithium-based cathode, and an electrolyte.

Claims

1. A pouch cell comprising:

a copper foil forming a pouch;

an active material layer adjacent to the copper foil inside the pouch forming an anode with the copper;

a lithium-based cathode inside the pouch;

a separator interposing the one active material layer and the lithium-based cathode; and

an electrolyte.

2. The pouch cell of claim 1, wherein active material comprises an acidified metal oxide.

3. The pouch cell of claim 2, wherein the active material is applied in at least one layer inside the pouch with a density of about 6.49 mg/cm2.

4. The pouch cell of claim 3, wherein the separator comprises a pouch containing the lithium-based cathode.

5. The pouch cell of claim 4, wherein the separator comprises polypropylene.

6. The pouch cell of claim 5, wherein the pouch comprises a unitary segment of copper foil folded to create the pouch.

7. The pouch cell of claim 6, wherein the segment of copper foil has a folded edge forming a bottom of the pouch and opposite sides of the pouch adjacent to the folded bottom edge are sealed together.

8. The pouch cell of claim 7, further comprising a first terminal tab electrically connected to the lithium-based cathode and accessible outside the pouch.

9. The pouch cell of claim 8, further comprising a second terminal tab electrically connected to the copper foil pouch.

10. The pouch cell of claim 9, wherein the lithium-based cathode is a lithium foil.

11. The pouch cell of claim 10, wherein the lithium-based cathode consists of metallic lithium.

12. The pouch cell of claim 11, further comprising an insulating layer applied to an outside of the copper foil pouch.

13. The pouch cell of claim 12, wherein the insulating layer comprises polyisobutylene.

14. A method of forming a battery cell comprising:

preparing a copper foil pouch;

lining an interior portion of the copper foil pouch with an active material to create an anode pouch;

providing a lithium-based foil cathode surrounded by a separator inside the pouch;

providing an electrolyte inside the pouch; and

sealing the pouch.

15. The method of claim 14, further comprising providing attaching a first electrical tab as a terminal to the cathode inside the pouch and routing the electrical tab to outside the pouch.

16. The method of claim 15, further comprising affixing a second electrical tab to the copper foil pouch.

17. The method of claim 15, further comprising coating an outside of the copper foil pouch with an insulating material.

18. A battery cell comprising:

a copper foil pouch having an opening end and a folded end and opposite sealed-together sides;

an active material lining the copper foil pouch;

a segment of lithium foil inside a separator inside the pouch;

a first terminal affixed to the lithium foil and accessibly outside the pouch;

wherein the copper foil pouch contains an electrolyte; and

wherein the copper foil pouch is sealed at the opening end and encloses the lithium foil, separator, and electrolyte inside the pouch, and provides a working voltage between the copper pouch and the first terminal.

19. The battery cell of claim 18, wherein the copper foil has a second terminal affixed thereto and provides the working voltage between the first and second terminals.

20. The battery cell of claim 19, further comprising an electrically insulating polymer coating applied to an outside of the copper foil pouch.