Current collection through thermally sprayed tabs at the ends of a spirally wound electrochemical cell
First Claim
Patent Images
1. A method of making an electrochemical cell comprising the steps of:
- providing a first conductive sheet having a first end;
providing a layer of insulation on said first conductive sheet such that said layer of insulation covers less than the entire area of said first conductive sheet;
providing a second conductive sheet having a first end;
laying said second conductive sheet on said layer of insulation such that said first end of said second conductive sheet is substantially parallel to said first end of said first conductive sheet but is offset in a direction transverse to said first ends;
rolling said first conductive sheet, said layer of insulation, and said second conductive sheet together to form a jelly-roll stack having a longitudinal axis transverse to said first ends of said first and second conductive sheets such that the first end of said first conductive sheet forms a spiral space at a first end of the stack;
spraying a first conductive material along a first spray path onto said first end of said stack such that said conductive material does not contact said second conductive sheet, said first spray path forming an angle of between 20° and
80°
with respect to said longitudinal axis.
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Abstract
A method of making an electrochemical cell, and an electrode stack made thereby. The method includes fabrication of a coating onto selected areas of the ends of the stack by a thermal spray coating process in which the coating is applied to one of the electrodes in the stack without the coating contacting the alternate edges of the other electrode in the stack. Suitable conductive strips, compatible with the substrate materials that make up the electrodes of the cell, can be attached to the thermally sprayed coating layers, or can be embedded into the sprayed materials as they are applied to the electrode stack.
415 Citations
25 Claims
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1. A method of making an electrochemical cell comprising the steps of:
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providing a first conductive sheet having a first end;
providing a layer of insulation on said first conductive sheet such that said layer of insulation covers less than the entire area of said first conductive sheet;
providing a second conductive sheet having a first end;
laying said second conductive sheet on said layer of insulation such that said first end of said second conductive sheet is substantially parallel to said first end of said first conductive sheet but is offset in a direction transverse to said first ends;
rolling said first conductive sheet, said layer of insulation, and said second conductive sheet together to form a jelly-roll stack having a longitudinal axis transverse to said first ends of said first and second conductive sheets such that the first end of said first conductive sheet forms a spiral space at a first end of the stack;
spraying a first conductive material along a first spray path onto said first end of said stack such that said conductive material does not contact said second conductive sheet, said first spray path forming an angle of between 20° and
80°
with respect to said longitudinal axis.- View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9)
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10. A method of making an electrochemical cell comprising the steps of:
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providing a first conductive sheet having a first end;
providing a layer of insulation on said first conductive sheet such that said layer of insulation covers less than the entire area of said first conductive sheet;
providing a second conductive sheet having a first end;
laying said second conductive sheet on said layer of insulation such that said first end of said second conductive sheet is substantially parallel to said first end of said first conductive sheet but is offset in a direction transverse to said first ends;
rolling said first conductive sheet, said layer of insulation, and said second conductive sheet together to form a jelly-roll stack having a longitudinal axis transverse to said first ends of said first and second conductive sheets such that the first end of said first conductive sheet forms a spiral space at a first end of the stack; and
spraying a first conductive material along a first spray path onto said first end of said stack such that said conductive material does not contact said second conductive sheet, said first spray path forming an angle of between 20° and
80°
with respect to said longitudinal axis, further comprising the step of placing a conductive strip on the first end of said first conductive sheet before said spraying step.- View Dependent Claims (11, 12, 13, 14, 15)
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16. A method of making an electrochemical cell having first and second electrodes extending substantially parallel to one another and separated by an insulating material, said electrodes being arranged in a rolled stack having a longitudinal axis, said first electrode extending farther along said longitudinal axis than said second electrode at a first end of said stack to form a first end face having a spiral space therein, said method comprising the step of:
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disposing a mask over said first end of said stack to expose only a portion of said first end face; and
spraying conductive material along a first spray path onto said first end of said stack such that said conductive material enters said spiral space only at said exposed portion of said first end face, said first spray path forming an angle of between 20° and
80°
with respect to said longitudinal axis.- View Dependent Claims (17, 18, 19, 20, 21, 22, 23)
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24. A method of making an electrochemical cell comprising the steps of:
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providing a first conductive sheet having a first end;
providing a layer of insulation on said first conductive sheet such that said layer of insulation covers less than the entire area of said first conductive sheet;
providing a second conductive sheet having a first end;
laving said second conductive sheet on said layer of insulation such that said first end of said second conductive sheet is substantially parallel to said first end of said first conductive sheet but is offset in a direction transverse to said first ends;
rolling said first conductive sheet, said layer of insulation, and said second conductive sheet together to form a jelly-roll stack having a longitudinal axis transverse to said first ends of said first and second conductive sheets such that the first end of said first conductive sheet forms a spiral space at a first end of the stack; and
spraying a first conductive material along a first spray path onto said first end of said stack such that said conductive material does not contact said second conductive sheet, said first spray path forming an angle of between 20° and
80°
with respect to said longitudinal axis, further comprising the step of spraying a second material onto said first end along a second spray path which is at an angle with respect to said first spray path.- View Dependent Claims (25)
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Specification