Compact lithium ion battery and method of manufacturing

• US 6,406,815 B1
• Filed: 02/11/2000
• Issued: 06/18/2002
• Est. Priority Date: 02/11/2000
• Status: Expired due to Term

• Current Assignee: EnerDel, Inc. (Ener1, Inc.)
• Original Assignee: Delphi Technologies, Inc. (BorgWarner Incorporated)
• Inventors: Sandberg, Murray G., Benson, Morgan Rey
• Primary Examiner(s): Brouillette, Gabrielle
• Assistant Examiner(s): Martin, Angela J.
• Application Number:
  US09/502,706
• Time in Patent Office: 858 Days
• Field of Search: 429/231.95, 429/162, 429/163, 429/124, 429/127, 429/152, 296/231
• US Class Current: 429/231.95
• 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 10/0436 Small-sized flat cells or batteries for portable equipment
• CPC Class Codes: H01M 50/536 characterised by the method of fixing the leads to the electrodes, e.g. by welding
• 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: 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 29/49108 Electric battery cell making
• CPC Class Codes: Y10T 29/4911 including sealing
• CPC Class Codes: Y10T 29/49114 including adhesively bonding

Abstract

Described is a lithium ion battery 10 comprising:

A housing having a front side 13 and a backside 15 and an anode cell terminal 60 and a cathode cell 44 terminal separated therefrom;

Positioned within the housing a plurality of bipolar lithium ion cells 40 having an lithium ion permeable plastic separator 32 there between; the cell electrodes being comprised of a thin film plastic substrate 34 and being electrically connected appropriately to the anode and the cathode cell terminals;

wherein the cells are longitudinally placed in the housing parallel to the sides of the housing; and

wherein the housing is enclosed by the cathode cell terminal at one end and the anode cell terminal at the opposite end of the cell sleeve; and

the enclosed housing is capable of receiving an electrolyte placed between the cells and the electrolyte is capable of carrying ions between the anode and the cathode. Also described is a method of manufacturing the lithium ion batteries.

Claims

1. A lithium ion battery comprising:

a housing having a front side and a backside and an anode terminal and a cathode terminal separated therefrom;

positioned within the housing a plurality of bipolar lithium ion cells having a polymer separator therebetween;

the cell electrodes being comprised of a thin film plastic substrate and being electrically connected to the anode and the cathode cell terminals;

wherein the cells are longitudinally placed in the housing parallel to the sides of the housing;

wherein the housing is enclosed by the cathode cell terminal at one end and the anode cell terminal at the opposite end of the housing; and

wherein the one of the terminals has a port for insertion of electrolyte into the battery after assembly of the cells within the housing;

the enclosed housing optionally containing an electrolyte placed between the cells, wherein the electrolyte carries ions between the anode and the cathode.

2. A lithium ion battery comprising:

a housing having a front side and a backside and an anode terminal and a cathode terminal separated therefrom;

positioned within the housing a plurality of bipolar lithium ion cells having a polymer separator therebetween;

the cell electrodes being comprised of a thin film plastic substrate and being electrically connected appropriately to the anode and the cathode cell terminals;

wherein the cells are longitudinally placed in the housing parallel to the sides of the housing;

wherein the housing is enclosed by the cathode cell terminal at one end and the anode cell terminal at the opposite end of the housing;

wherein one of the terminals has a vent for gas release therefrom;

the enclosed housing optionally containing an electrolyte placed between the cells and the electrolyte carries ions between the anode and the cathode.

3. A lithium ion battery comprising:

a housing having a front side and a backside and an anode terminal and a cathode terminal separated therefrom;

positioned within the housing a plurality of bipolar lithium ion cells having a polymer separator therebetween;

the cell electrodes being comprised of a thin film plastic substrate and being electrically connected appropriately to the anode and the cathode cell terminals;

wherein the cells are longitudinally placed in the housing parallel to the sides of the housing;

wherein the housing is enclosed by the cathode cell terminal at one end and the anode cell terminal at the opposite end of the housing;

wherein the cells are retained within a cell sleeve surrounding the longitudinal length of the cells within the housing;

wherein the cell sleeve extends beyond the length of the cells and which extensions are retained in a plurality of metallic clips, one of which is the anode and another is the cathode;

the enclosed housing optionally containing an electrolyte placed between the cells and the electrolyte carries ions between the anode and the cathode.