Electrochemical cell stack and method of making an electrochemical cell stack
First Claim
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1. An electrochemical cell stack, comprising:
- a continuous laminate web, the continuous laminate web having one continuous first polarity electrode layer, one continuous electrolyte layer, and a plurality of discrete second polarity electrode segments secured on top of the electrolyte layer in predetermined locations, the continuous laminate web being fan-folded at predetermined fold positions such that the second polarity electrode segments contact the electrolyte layer on top and bottom sides of each of the second polarity electrode segments, the fan-folded continuous laminate web forming a stack having first and second sides;
second polarity electrode current collector means for collecting second polarity electrode current; and
first polarity electrode current collector means for collecting first polarity electrode current.
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Abstract
An electrochemical cell stack is made from a continuous laminate web including an electrode layer, an electrolyte layer, and a plurality of discrete opposite polarity electrode segments. The laminate is fan-folded into a stack such that substantially the entire surface area of the opposite polarity electrode segments are in contact with the electrolyte layer and in ion exchange with the electrode layer. Current can collected from the discrete opposite polarity electrode segments by opposite polarity electrode current collector strips that electrically connect the opposite polarity electrode segments. A method for making an electrochemical cell stack is also disclosed.
148 Citations
31 Claims
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1. An electrochemical cell stack, comprising:
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a continuous laminate web, the continuous laminate web having one continuous first polarity electrode layer, one continuous electrolyte layer, and a plurality of discrete second polarity electrode segments secured on top of the electrolyte layer in predetermined locations, the continuous laminate web being fan-folded at predetermined fold positions such that the second polarity electrode segments contact the electrolyte layer on top and bottom sides of each of the second polarity electrode segments, the fan-folded continuous laminate web forming a stack having first and second sides; second polarity electrode current collector means for collecting second polarity electrode current; and first polarity electrode current collector means for collecting first polarity electrode current. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 24, 25)
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13. A laminate for forming an electrochemical cell stack, comprising:
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one continuous first polarity electrode layer having a first and a second surface; one continuous electrolyte layer having a first and a second surface, the first surface of the electrolyte layer being attached to the second surface of the first polarity electrode layer; a plurality of discrete second polarity electrode segments each having a first and a second surface, the first surface of each second polarity electrode segment being secured on the second surface of the electrolyte layer; the laminate being foldable at a plurality of predetermined fold positions such that at least a portion of the second surface of each second polarity electrode segment contacts a portion of the second surface of the electrolyte layer. - View Dependent Claims (14, 15, 16, 17, 18, 26, 27)
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19. A method of making an electrochemical cell stack, comprising the steps of:
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coating a top surface of one continuous first polarity electrode layer with one continuous electrolyte layer; securing a plurality of second polarity electrode segments on a top surface of the continuous electrolyte layer to form a laminate, the plurality of second polarity electrode segments being secured in predetermined locations on the laminate; fan-folding the laminate at predetermined fold positions such that the second polarity electrode segments contact the electrolyte layer on first and second sides of the second polarity electrode segments, the fan-folding forming a stack having first and second sides; and attaching second polarity electrode current collector means to the second polarity electrode segments in predetermined locations and first polarity electrode current collector means to the first polarity electrode layer. - View Dependent Claims (20, 21, 28, 29)
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22. A method of making a laminate for making an electrochemical cell stack, comprising the steps of:
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coating a top surface of one continuous first polarity electrode layer with one continuous electrolyte layer; and securing a plurality of second polarity electrode segments on a top surface of the continuous electrolyte layer, the plurality of second polarity electrode segments being secured in predetermined locations. - View Dependent Claims (23, 30, 31)
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Specification