Electrochemical cell with improved efficiency serpentine electrode

• US 5,147,737 A
• Filed: 05/07/1991
• Issued: 09/15/1992
• Est. Priority Date: 05/07/1991
• Status: Expired due to Term

• Current Assignee: Greatbatch Limited (Greatbatch Incorporated)
• Original Assignee: Wilson Greatbatch Technologies, Inc.
• Inventors: Post, Clifford J., Takeuchi, Esther S.
• Primary Examiner(s): Bell, Mark L.
• Assistant Examiner(s): JONES, DEBORAH D
• Application Number:
  US07/696,711
• Time in Patent Office: 497 Days
• Field of Search: 429/94, 429/241, 429/137, 429/246, 29/623.3, 29/623.4
• US Class Current: 429/94
• CPC Class Codes: H01M 10/0413 Large-sized flat cells or batteries for motive or stationary systems with plate-like electrodes
• CPC Class Codes: H01M 10/0454 Cells or batteries with electrodes of only one polarity folded
• CPC Class Codes: H01M 6/10 with wound or folded electrodes
• CPC Class Codes: H01M 6/16 with organic electrolyte H01M6/18 takes precedence
• 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 29/49112 including laminating of indefinite length material
• CPC Class Codes: Y10T 29/49114 including adhesively bonding

Abstract

An electrochemical cell having a serpentine-like electrode wherein electrode active material thereon is distributed for maximizing capacity and minimizing volume. The electrode active material extends along the length of the current collecting element of the electrode and terminates at a fold which defines an outer side of an outer section so that electrode active material is not positioned on this outer side where it would not be facing an opposite polarity electrode and where it may thus be generally ineffective for increasing battery capacity. The resulting savings in volume allows the thickness of the electrode active layer to be increased so that additional battery capacity may be achieved in the same battery volume.

Claims

1. A cell for providing an electric current comprising a casing, a first electrode means in said casing, a second electrode means in said casing, an electrolyte in said casing and in contact with said first and second electrode means, means for providing electrical connection to said first electrode means, means for providing electrical connection to said second electrode means, and means for separating said first and second electrode means, said first electrode means comprising a plurality of plates in spaced apart relation, and said second electrode means comprising an elongate sheet of electrically conductive material having a pair of sides, a pair of longitudinal edges, and a pair of end edges and which is folded at spaced intervals along the length thereof to form a serpentine-like structure having a plurality of spaced sections, said plates disposed between said sections respectively in an alternating relationship, said second electrode means further comprising at least one layer of electrode active material on each of said sides, said plurality of spaced sections including a pair of end sections each having a side which is a portion of one of said sheet sides and which faces outwardly of said serpentine-like structure whereby said end section side does not face any of said plates, said at least one layer of electrode active material on said one sheet side extends along the length of said sheet to and terminates at the fold defining said end section side whereby said end section side is substantially free of electrode active material.

2. A cell according to claim 1 wherein said electrode active material is composed of an alkali metal.

3. A cell for providing an electric current comprising a casing, an anode means in said casing, a cathode means in said casing, an electrolyte in said casing and in contact with said anode means and said cathode means, means for providing electrical connection to said anode means, means for providing electrical connection to said cathode means, and means for separating said anode means and said cathode means, said cathode means comprising a plurality of plates in spaced apart relation, and said anode means comprising an elongate-sheet of electrically conductive material-.having a pair of sides, a pair of longitudinal edges, and a pair of end edges and which is folded at spaced intervals along the length thereof to form a serpentine-like structure having a plurality of spaced sections, said plates disposed between said sections respectively in an alternating relationship, said anode means further comprising at least one layer of material composed of lithium on each of said sides, said plurality of spaced sections including a pair of end sections each having a side which is a portion of one of said sheet sides and which faces outwardly of said serpentine-like structure whereby said end section side does not face any of said plates, said at least one layer of lithium material on said one sheet side extends along the length of said sheet to and terminates at the fold defining said end section side whereby said end section side is free of lithium material

4. A cell according to claim 3 wherein said cathode means comprises as active material silver vanadium oxide

5. cell according to claim 4 wherein said electrolyte is a combination of a lithium salt and an organic solvent

6. A cell according to claim 3 wherein said electrolyte is a combination of a lithium salt and an organic solvent

7. A cell according to claim 3 wherein said at least one layer of lithium material is in the form of a foil

8. A cell according to claim 3 wherein said electrically conductive material is a screen composed of nickel.

9. A method of making an electrode for an electrochemical cell comprising the steps of (a) folding an elongate sheet of electrically conductive material at spaced intervals along the length thereof to form a serpentine-like structure having a plurality of spaced sections for receiving therebetween electrode plates respectively and whereby each of a pair of end sections of the plurality of spaced sections has a side which is a portion of one of the sheet sides and which faces outwardly of the serpentine-like structure, and (b) applying at least one layer of electrode active material of opposite polarity to each sheet side so that the layer on one of the sheet sides extends along the length of the sheet to said end section side and terminates at the fold defining said end section side whereby said end section side is free of electrode active material.

10. A method according to claim 9 comprising performing step (b) before step (a).

11. A method according to claim 9 comprising selecting the electrode active material to be composed of an alkali

12. A method according to claim 9 comprising selecting the electrode active material to be composed of lithium.

13. A method according to claim 12 further comprising selecting the electrically conductive material to be a screen composed of nickel.

14. A method according to claim 12 further comprising selecting the at least one layer of electrode active material to be in the form of an extruded foil.

15. A method according to claim 14 further comprising selecting the electrically conductive material to be a metallic screen and pressing the foils onto the respective sides of the screen.