Electrical contact outlet for anodes

• US 5,415,954 A
• Filed: 04/27/1993
• Issued: 05/16/1995
• Est. Priority Date: 05/08/1992
• Status: Expired due to Term

• Current Assignee: Avestor (Bolloré SE)
• Original Assignee: Hydro-Quebec (Province of Québec)
• Inventors: Gauthier, Michel, St-Amant, Guy, Ricard, Serge, Jacobs, James K., Belanger, Andre
• Primary Examiner(s): KALAFUT, STEPHEN J
• Application Number:
  US08/052,833
• Time in Patent Office: 749 Days
• Field of Search: 429/94, 429/211, 429/161
• US Class Current: 429/94
• CPC Class Codes: H01M 4/661 Metal or alloys, e.g. alloy coatings H01M4/669 take precedence
• CPC Class Codes: H01M 50/528 Fixed electrical connections, i.e. not intended for disconnection
• CPC Class Codes: H01M 50/534 characterised by the material of the leads or tabs
• CPC Class Codes: H01M 50/538 Connection of several leads or tabs of wound or folded electrode stacks
• CPC Class Codes: H01M 6/46 of flat cells
• CPC Class Codes: Y02P 70/50 Manufacturing or production processes characterised by the final manufactured product

Abstract

Electrical contact outlet for an anode sheet of a lithium generator with polymer electrolyte, consisting of one or more multilayer electrochemical cells. The cell comprises at least one lithium base sheet having a thickness between about 1 and 50 microns to constitute the anode and its collector and additionally includes a cathode and its collector as well as the polymer electrolyte. A lateral end of the anode sheet extends beyond corresponding ends of the cathode and the collector to constitute a projecting zone. A metallic layer consisting of at least one rigid metal which is compatible with lithium is in electrical contact with the lateral end of the anode sheet but without electronic contact with the other components of the cell. The metallic layer constitutes the external terminal of the generator when the latter is in non-finished condition. According to a variant, a conductive and cohesive intermediate metallic zone, which consists of lithium or lithium rich ductile alloys is in intimate contact with the lateral end of the anode sheet and the metallic layer mentioned above is therefore in electrical contact with the lateral end of the anode sheet by means of the intermediate zone of lithium. Generators provided with such contact outlet as well as a process for the preparation of these contact outlets are described.

Claims

1. In a polymer electrolyte lithium generator comprising at least one multilayer electrochemical cell, each layer of said cell comprising a laminated combination of at least part of a lithium base strip, said strip having opposite ends and opposite edges, said strip having a thickness between about 1 and 50 microns constituting the anode of said cell layer, a collector for said anode, a cathode and a collector for said cathode, a polymer electrolyte disposed between said anode and said cathode, said collectors, said cathode and said polymer electrolyte being also in strip forms, and an electrical contact outlet for the anodes of said at least one multilayer electrochemical cell, the improvement wherein in each said layer at least one edge of said anode extends beyond corresponding edges of said cathode and said collectors to constitute a plurality of anode projections for said multilayer electrochemical cell, said anode projections being equal in number to the number of layers, said electrical contact outlet device for said anodes comprises a metallic layer consisting of at least one rigid metal which is compatible with lithium, said metallic layer being in intimate electrical contact with substantially the entire extending edges of said anodes at one end of the cell, through said anode projections.

2. Polymer electrolyte lithium generator according to claim 1, wherein said generator consists of at least one coiled multilayer electrochemical cell.

3. Polymer electrolyte lithium generator according to claim 1, wherein said generator consists of at least one multilayer electrochemical cell in stacked or zig-zag arrangement.

4. Polymer electrolyte lithium generator according to claim 1, wherein said metallic layer is between 0.05 and 2 mm thick.

5. Polymer electrolyte lithium generator according to claim 4, wherein said metallic layer consists of copper, nickel, iron or alloys thereof.

6. Polymer electrolyte lithium generator according to claim 1, wherein said metallic layer is obtained by pulverization of said metal, either in liquid or semi-liquid form, so as to enable said metallic layer to follow the contour of the edges of the strips of lithium at one end of the cell.

7. Polymer electrolyte lithium generator according to claim 1, wherein said electrical control outlet device contains a conductive and cohesive intermediate metallic zone, consisting of lithium or lithium rich ductile alloys, in intimate contact with said strip at one end of the cell, said metallic layer being in electrical contact with said edges of said anode strip by means of said intermediate metallic zone.

8. Polymer electrolyte lithium generator according to claim 1, wherein the anode strip consists of lithium or a lithium rich alloy or compound.

9. Polymer electrolyte lithium generator according to claim 1, wherein the anode projections are non-supported, the width of said anode projections representing less than about 10% of the useful width of said anode strip.

10. Polymer electrolyte lithium generator according to claim 1, wherein the anode projections are non-supported, the width of said anode projections representing less than about 5% of the useful width of said anode strip.

11. Polymer electrolyte lithium generator according to claim 1, wherein the anode strip is supported on a plastic film consisting either of an insulating film, having a thickness lower than 10 microns, or the polymer electrolyte per se whose thickness is between 5 and 100 microns, the width of the anode projections of the anode strip representing less than about 5% of the useful width of the anode sheet.

12. Polymer electrolyte lithium generator according to claim 11, wherein the insulating film consists of polypropylene or polyethylene.

13. Polymer electrolyte lithium generator according to claim 7, wherein the intermediate metallic zone is formed by the projections of said anode strip, combined in electrical contact with one another so as to consolidate said edges of said anode strip of said cell at one end of the cell and to protect other components, including the insulating film of said cell.

14. Polymer electrolyte lithium generator according to claim 7, wherein said intermediate metallic zone has a thickness between 0.1 and 2 mm and is applied on the edges of the anode strip or strips at one end of the cell.

15. Polymer electrolyte lithium generator according to claim 14, wherein said intermediate metallic zone is also applied on faces of said anode strip in the anode projections of the latter.

16. Polymer electrolyte lithium generator according to claim 14, wherein said intermediate metallic zone consists mainly of lithium or its low melting alloys whose lithium content is higher than 80% atomic and in which the melting temperature is lower than 250°

C.

17. Polymer electrolyte lithium generator according to claim 16, wherein said low melting alloys are selected from Li-Ca, Li-Mg, Li-Na, Li-Sr.

18. Polymer electrolyte lithium generator according to claim 7, wherein said metallic layer has a thickness between 0.05 and 2 mm.

19. Polymer electrolyte lithium generator according to claim 18, wherein said metallic layer consists of copper, nickel, iron or alloys thereof.

20. Polymer electrolyte lithium generator according to claim 7, wherein said metallic layer is obtained by pulverizing said metal, in liquid or semi-liquid form.

21. Polymer electrolyte lithium generator according to claim 7, wherein said metallic layer consists of a sheet or a grid welded to said intermediate metallic zone.

22. Polymer electrolyte lithium generator according to claim 21, wherein said sheet or said grid has a thickness between about 0.1 and 2 mm and consists of copper, nickel, iron, molybdenum, titanium or alloys thereof.

23. Polymer electrolyte lithium generator according to claim 7, wherein said intermediate metallic zone consists of projecting zones of said anode sheet welded with one another.

24. Multilayer polymer electrolyte generator according to claim 1, and whose cathode is laterally collected by means of a second device consisting of a projection of its collector in electrical contact with a collection metallic layer.

25. Generator according to claim 24, wherein said collection metallic layer consists of zinc, Al, Ag or alloys thereof.

26. Generator according to claim 24, wherein the collection metallic layers obtained by pulverization on the edges of the cathode collector.

27. Generator according to claim 24, wherein the collection metallic layer is obtained by shooping.

28. Multilayer polymer electrolyte generator according to claim 1 disposed in an external metallic casing in direct contact with the external metallic casing so as to optimize heat exchanges through the anode, and in which the cathode is laterally collected by means of a second device consisting of a projection of its collector in electrical contact with a collection metallic layer.

29. Generator according to claim 28, wherein said collection metallic layer consists of Zn, Al, Ag or alloys thereof.

30. Generator according to claim 28, wherein the collection metallic layer is obtained by pulverization on the edges of the cathode collector.

31. Generator according to claim 28, wherein the collection metallic layers are obtained by shooping.

32. Process for providing a polymer electrolyte lithium generator with an electrical contact outlet device, said generator comprising at least one multilayer electrochemical cell, each layer of said cell comprising a laminated combination of at least part of a lithium base strip, said strip having opposite ends and opposite edges, said strip having a thickness between about 1 and 50 microns forming an anode of said cell layer, a collector for said anode, a cathode and a collector for said cathode, a polymer electrolyte disposed between said anode and said cathode, said collectors, said cathode and said polymer electrolyte being also in strip forms, and an electrical contact outlet device for the anode of said at least one multilayer electrochemical cell, which comprises assembling said polymer electrolyte lithium generator so that in each said layer at least one edge of said anode extends beyond the corresponding edges of said cathode and said collectors to constitute a plurality of anode projections for said multilayer electrochemical cell, said anode projections being equal in number to the number of layers, depositing a metallic layer consisting of at least one metal which is rigid and compatible with lithium at the level of said anode projections so that said metallic layer be in intimate electrical contact with substantially the entire extending edges of said anodes at one end of the cell through said anode projections.

33. Process according to claim 32, wherein said electrochemical cell is prepared as a coiled multilayer.

34. Process according to claim 32, wherein said electrochemical cell is prepared as a stacked multilayer.

35. Process according to claim 32, wherein said metallic layer is deposited at a thickness between 0.05 and 2 mm.

36. Process according to claim 35, wherein said metallic layer consists of copper, nickel, iron or alloys thereof.

37. Process according to claim 32, wherein said metallic layer is obtained by pulverizing said metal, in liquid or semi-liquid form, so that said metallic layer follows the contour of the edges of the strips of lithium at one end of the cell.

38. Process according to claim 32, which comprises forming a conductive and cohesive intermediate metallic zone, consisting of lithium or lithium rich ductile alloys, in intimate contact with edges of said anode strip at one end of the cell, said metallic layer being in electrical contact with edges of said anode strip by means of said intermediate zone.

39. Process according to claim 32, wherein the anode strip consists of lithium or a lithium rich compound.

40. Process according to claim 32, wherein the anode projections are non-supported, and the width of said anode projections represents less than about 10% of the useful width of said anode strip.

41. Process according to claim 32, wherein anode projections are non-supported, and the width of said anode projections represents less than about 5% of the useful width of said anode strip.

42. Process according to claim 32, wherein the anode strip is supported on a plastic film consisting either of an insulating film, having a thickness lower than 10 microns, or on the polymer electrolyte per se whose thickness is between 5 and 100 microns, and the width of the anode projections of the anode strip represents less than about 5% of the useful width of the anode strip.

43. Process according to claim 42, wherein the insulating film consists of polypropylene or polyethylene.

44. Process according to claim 43, wherein the intermediate metallic zone is formed by the combination of the anode projections of said edges of said anode sheet so as to be in electrical contact with one another to consolidate said lateral edges of said anode strip of said cell at one end of the cell and to protect other parts, including the insulating film of said cell.

45. Process according to claim 44, wherein the anode projections of said lateral edges of said anode strip at one end of the cell are mechanically united.

46. Process according to claim 44, wherein the anode projections of said lateral edges of said anode strip at one end of the cell are thermally united.

47. Process according to claim 44, wherein the anode projections of said lateral edges of said anode strip at one end of the cell are united by mechanical pressing of said strips with one another at the level of said anode projections.

48. Process according to claim 44, wherein the anode projections of said lateral edges at one end of the cell are united by ultrasonic welding.

49. Process according to claim 44, characterized in that the anode projections of said lateral edges at one end of the cell are united by local melting of the anode strips.

50. Process according to claim 44, wherein the intermediate metallic zone is prepared by application, under inert atmosphere, of an added metal containing lithium or alloys thereof in molten or semi-molten state, through mechanical pulverization, pulverization under an electric arc, or application of lithium or its low melting alloys, so as to give a deposit which is conductive and cohesive and which consolidates the edge of the anode strip of the cell.

55. Process according to claim 38, wherein the application of the metal or metals in the intermediate zone is selected from processes of mechanical pulverization of molten lithium under a jet of inert gas at a temperature between 150°

and 250°

C., processes of pulverization under an electric arc utilizing lithium in the form of rods and processes of welding by direct contact with molten lithium, as an alloy melting below the melting point of lithium.

56. Process according to claim 43, wherein the process of pulverization under an electric arc uses rods of lithium produced by local extrusion directly in a shooping device.

57. Process according to claim 32, wherein said metallic layer is deposited at a thickness between 0.1 and 2 mm by application of Cu, Ni, Fe or alloys containing these elements by pulverization processes, through plasma pulverization under an inert gas or under an electric arc with an inert gas or air in the case of copper and nickel.

58. Process according to claim 38, wherein said metallic layer is deposited at a thickness between 0.1 and 2 mm by application of a sheet or grid of Cu, Ni, Fe, Mo, Ti or alloys containing these elements, and forming an electrical, thermic or mechanical weld between this sheet and the alloy of lithium of the intermediate zone, by spot-welding, by local melting of lithium alloy or by ultrasonic waves.

59. Process according to claim 32, wherein the anode strips are stacked by cylindrical winding or in flat condition, or by zig-zag or discontinuous stacking.

60. Process according to claim 32, which comprises providing a lateral contact at the opposite edge of the anode by aluminum or zinc shooping on a projection of the collector metal of the cathode, so as to provide two electrical contacts.

61. Process according to claim 32, wherein the operations of applying contact outlets on the generator are carried out in air, by pulverization under electric arc with zinc or aluminum for the cathode and copper or nickel for the metallic layer of the anode.

51. Process according to claim 51, wherein said intermediate metallic zone is prepared at a thickness between 0.1 and 2 mm and it is applied on the edge of said anode strip or strips.

52. Process according to claim 51, wherein said intermediate metallic zone is also applied on the faces of said anode strip in the anode projection of the latter.

53. Process according to claim 52, wherein said intermediate metallic zone consists mainly of lithium or its low melting alloys whose lithium content is higher than 80% atomic and whose melting temperature is lower than 250°

C.

54. Process according to claim 53, wherein said low melting alloys are selected from Li-Ca, Li-Mg, Li-Na, Li-Sr.