Electric storage battery construction and method of manufacture

• US 7,416,811 B2
• Filed: 01/15/2003
• Issued: 08/26/2008
• Est. Priority Date: 01/15/2002
• Status: Active Grant

• Current Assignee: Quallion, LLC (EnerSys)
• Original Assignee: Quallion, LLC (EnerSys)
• Inventors: Yumoto, Hiroyuki, Tsukamoto, Hisashi, Skinlo, David M., Nagata, Mikito, Nakahara, Hiroshi
• Primary Examiner(s): Ryan; Patrick
• Assistant Examiner(s): MARTIN, ANGELA J
• Application Number:
  US10/478,706
• Publication Number:
  US 20050031960A1
• Time in Patent Office: 2,050 Days
• Field of Search: 429/94, 429/164, 429/166, 429/161, 429/169, 429/170, 429/178, 429/176, 429/211, 429/60
• US Class Current: 429/94
• CPC Class Codes: H01M 10/0431 Cells with wound or folded electrodes H01M10/045 takes precedence
• 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 10/0587 of accumulators having only wound construction elements, i.e. wound positive electrodes, wound negative electrodes and wound separators
• CPC Class Codes: H01M 50/528 Fixed electrical connections, i.e. not intended for disconnection
• CPC Class Codes: H01M 6/16 with organic electrolyte H01M6/18 takes precedence
• 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 29/49114 including adhesively bonding

Abstract

An electric storage battery and method of manufacture thereof. Active material (78) is removed from both sides of the outer end (88) of the negative electrode (70) in a jellyroll (84) to allow room for adhesive tape (96) to secure the jellyroll.

Claims

1. A battery, comprising:

a first polarity electrode strip that includes a first coating on faces of an elongate first substrate, the first coating including an active material;

a second polarity electrode strip configured to serve as a negative electrode, the second polarity electrode strip including a second coating on faces of an elongate second substrate, the second coating including lithium metal;

the first polarity electrode strip and the second polarity electrode strip being interleaved with a separator and wound together so as to form a spiral roll configured such that;

the first polarity electrode strip has an inner end and an outer end,

the second polarity electrode strip has an inner end and an outer end,

the second polarity electrode strip is outermost of the first polarity electrode strip and the second polarity electrode strip for one full turn of the spiral roll,

the separator is outermost of the separator, the first polarity electrode strip and the second polarity electrode strip, and

the second polarity electrode strip includes an exposed region where the faces of the second substrate are devoid of the second coating,

the exposed region is located at the outer end of the second polarity electrode strip such that the portion of the second polarity electrode strip that is outermost on the roll includes

a first region where a face of the second substrate is the outermost part of the second electrode, and

a second region where the second coating is the outermost part of the second electrode.

2. The battery of claim 1, wherein the second coating on each face of the second substrate is thicker than the second substrate.

3. The battery of claim 1, further including:

adhesive tape adhering the second substrate outer end to the roll.

4. The battery of claim 3, wherein the combined thickness of the second coating on each face of the second substrate is greater than the thickness of the adhesive tape.

5. The battery of claim 1, wherein the exposed region extends along a length of the second substrate that is between 1 and 8 mm.

6. The battery of claim 1, wherein the exposed region extends along a length of the second substrate that is about 2 mm.

7. The battery of claim 1, wherein the second polarity electrode strip is negative.

12. The battery of claim 1, wherein a length of the exposed region is different on one of the faces of the second substrate than on another of the faces of the second substrate.

13. The battery of claim 1, wherein the second polarity electrode strip inner end is devoid of active material on one of the faces of the second substrate for a first length;

and wherein

the second polarity electrode strip inner end is devoid of active material on another one of the faces of the second substrate for a second length different from the first length.

14. The battery of claim 1, wherein the first polarity electrode strip inner end is devoid of active material on both faces of the second substrate.

15. The battery of claim 1, wherein the first polarity electrode strip inner end is devoid of active material on one of the faces of the first substrate for a first length;

and wherein

said first polarity electrode strip inner end is devoid of active material on another of the faces of the second substrate for the first length.

16. The battery of claim 1, wherein the first polarity electrode strip outer end has active material on each face of the first substrate.

17. The battery of claim 1, wherein the lithium metal is lithium in its elemental and uncompounded form.

18. The battery of claim 17, wherein the second coating consists of the lithium metal.

19. The battery of claim 17, wherein the second coating consists of a lithium foil.

20. The battery of claim 19, wherein the lithium foil is laminated to the second substrate.

21. The battery of claim 1, wherein the second coating is laminated to the second substrate.

22. The battery of claim 1, further comprising:

an electrically conductive, elongate pin;

an elongate mandrel mounted on at least a portion of the pin, the mandrel including a longitudinal slot; and

the first polarity electrode strip extending through the mandrel slot and being in electrical communication with the pin.

8. A method for making a battery, comprising:

providing a first polarity electrode strip tat includes a first coating on faces of an elongate first substrate, the first coating including an active material;

providing a second polarity electrode strip configured to serve as a negative electrode, the second polarity electrode strip including a second coating on faces of comprising an elongate second substrate, having first and second faces each carrying a coat of active material, wherein an outer end is devoid of active material on both faces thereof the second coating including lithium metal; and

winding the first polarity electrode strip and the second polarity electrode strip together with a separator material so as to form a spiral roll configured such that;

the separator material is positioned between the first electrode strip and the second electrode strip,

the first polarity electrode strip has an inner end and an outer end,

the second polarity electrode strip has an inner end and an outer end,

the second polarity electrode strip is outermost of the first polarity electrode strip and the second polarity electrode strip for one full turn of the spiral roll,

the separator is outermost of the separator, the first polarity electrode strip, and the second polarity electrode strip, and

the second polarity electrode strip includes an exposed region where the faces of the second substrate are devoid of the second coating,

the exposed region is located at the outer end of the second polarity electrode strip such that the portion of the second polarity electrode strip that is outermost on the roll includes

a first region where a face of the second substrate is the outermost part of the second electrode, and

a second region where the second coating is the outermost part of the second electrode.

9. The method of claim 8, wherein the second coating on each face of the second substrate is thicker than the second substrate.

10. The method of claim 8, further comprising:

taping the outer end of the second polarity electrode strip to the roll.

11. The method of claim 8, wherein a combined thickness of the second coating on each face of the second substrate is greater than a thickness of an adhesive tape employed to tape the outer end of the second polarity electrode strip.