Process for manufacturing electrochemical cells

• US 6,287,721 B1
• Filed: 09/24/1999
• Issued: 09/11/2001
• Est. Priority Date: 09/24/1998
• Status: Expired due to Term

• Current Assignee: Inventus Power, Co.
• Original Assignee: Thomas & Betts International Incorporated (ABB Limited)
• Inventors: Roberts, Thomas J., Kaganovich, Steve, Xie, Like, Zang, Zhiwei, Alamgir, Mohammed
• Primary Examiner(s): Kalafut, Stephen
• Assistant Examiner(s): TSANG FOSTER, SUSY N
• Application Number:
  US09/405,200
• Time in Patent Office: 718 Days
• Field of Search: 429/127, 429/152, 429/158, 429/162, 429/154, 429/160, 429/149, 429/211, 296/231, 296/235
• US Class Current: 429/152
• 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 10/0431 Cells with wound or folded electrodes H01M10/045 takes precedence
• CPC Class Codes: H01M 10/0436 Small-sized flat cells or batteries for portable equipment
• CPC Class Codes: H01M 10/0459 Cells or batteries with folded separator between plate-like electrodes
• CPC Class Codes: H01M 10/0525 Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodes; Lithium-ion batteries
• CPC Class Codes: H01M 10/058 Construction or manufacture
• CPC Class Codes: H01M 50/103 prismatic or rectangular H01M50/109, H01M50/11 take precedence
• CPC Class Codes: H01M 50/105 Pouches or flexible bags
• CPC Class Codes: H01M 50/534 characterised by the material of the leads or tabs
• CPC Class Codes: H01M 50/54 Connection of several leads or tabs of plate-like electrode stacks, e.g. electrode pole straps or bridges
• CPC Class Codes: H01M 6/10 with wound or folded electrodes
• 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 manifold bi-cell assembly for electrochemical cells such as a polymer lithium ion battery is provided along with a method of manufacture thereof. The disclosed electrochemical cell includes an elongate planar separator or substrate formed of an elastic material. A plurality of discrete anodes with laterally offset leads is positioned in longitudinally spaced apart relationship to one another and positioned between a pair of substrates to create a sandwich assembly wherein adjacent anodes have a substrate interface therebetween. A plurality of cathodes with laterally offset leads corresponding in size, shape and number to the plurality of anodes is also positioned in longitudinal spaced apart relation on an opposed side of said substrate and overlying the anodes. The substrate is folded along its interfaces to create a manifold assembly wherein the anodes and cathodes are superimposed in a stacked configuration with the leads of the cathodes being offset from the leads of the anodes.

Claims

1. A method of forming an electrochemical cell assembly, comprising the steps of:

providing at least one elongate substrate having opposed planar surfaces;

providing a plurality of discrete anodes having laterally offset contact leads;

arranging said anodes at spaced apart locations longitudinally along one surface of said substrate with said laterally offset leads in an alternating pattern;

placing a plurality of discrete cathodes at spaced apart locations longitudinally along an opposed surface of said substrate overlying said anodes to form a plurality of spaced apart bi-cells; and

folding said substrate at a location between said spaced apart bi-cells to form a stacked cell assembly of alternating cathodes and anodes.

2. The method of claim 1 wherein said contact leads include a copper mesh tab laminated to each of said anodes.

3. The method of claim 1 wherein said cathodes include contact leads extending in a laterally offset relation therefrom and wherein said placing step includes arranging said cathodes with said laterally offset leads in an alternating pattern.

4. The method of claim 3 wherein said contact leads includes an aluminum mesh tab laminated to said each of said cathodes.

5. The method of claim 1 wherein a second substrate is overlyingly placed atop said longitudinally spaced anodes so as to to create a sandwich structure.

6. The method of claim 1 wherein spacing is preserved between adjacent bi-cells to create a bi-cell interface that accommodates said folding step.

7. The method of claim 6 wherein said substrate is slit to produce at least one electrochemical cell assembly having a plurality of bi-cells therein.

8. The method of claim 7 wherein said bi-cells are folded along said interfaces to form a Z-shaped assembly.

9. An electrochemical cell assembly, comprising:

an elongate planar substrate;

a plurality of anodes having lateral offset leads positioned in longitudinally spaced apart relationship on one surface of said substrate; and

a corresponding plurality of cathodes having laterally offset leads positioned in longitudinally spaced apart relation on an opposed side of said substrate overlying said anodes, said leads of said cathodes being offset from said leads of said anodes;

wherein said substrate is folded to a position wherein said anodes and said cathodes are superimposed in a stacked configuration.

10. The electrochemical cell assembly of claim 9 wherein said anode contact leads include a copper mesh tab laminated to each of said anodes.

11. The electrochemical cell assembly of claim 9 wherein said cathode contact leads include an aluminum mesh tab laminated to said each of said cathodes.

12. The electrochemical cell assembly of claim 9 wherein a second elongate planar substrate is overlappingly placed on said anodes so as to create a sandwich structure that preserves the longitudinal relation thereof.

13. The electrochemical cell assembly of claim 12 wherein a spacing is preserved between adjacent anodes to create a bi-cell interface that accommodates folding of said substrate along each said interface.

14. The electrochemical cell assembly of claim 13 wherein said substrate is slit to produce at least one electrochemical cell.

15. The electrochemical cell assembly of claim 14 wherein said bi-cells are folded along said interfaces to form a Z-shaped assembly.