Tabs for electrochemical cells

• US 20040185332A1
• Filed: 03/21/2003
• Published: 09/23/2004
• Est. Priority Date: 03/21/2003
• Status: Abandoned Application

• Current Assignee: Sion Power Corporation
• Original Assignee: Moltech Corporation
• Inventors: Botos, Ernest D.
• Application Number:
  US10/394,386
• Publication Number:
  US 20040185332A1
• Time in Patent Office: Days
• US Class Current: 429/96
• CPC Class Codes: H01M 50/103 prismatic or rectangular H01M50/109, H01M50/11 take precedence
• CPC Class Codes: H01M 50/533 characterised by the shape of the leads or tabs
• CPC Class Codes: H01M 50/534 characterised by the material of the leads or tabs
• 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 50/538 Connection of several leads or tabs of wound or folded electrode stacks
• CPC Class Codes: Y02E 60/10 Energy storage using batteries

Abstract

Disclosed is a tab for use with an electrochemical cell. The tab is designed so that it can be replicated relatively easily in an automated manufacturing process and/or so it can be properly positioned on an electrochemical cell utilizing an automated process. The tab preferably includes a contact lead, a neutral lead and one or more contact strips connecting the contact lead and the neutral lead.

Claims

1. A tab for use on a prismatic electrochemical cell, the tab for providing an electrical contact and comprising:

(a) a contact lead;

(b) a neutral lead; and

(c) one or more contact strips connecting the contact lead and the neutral lead.

2. The tab of claim 1 wherein the neutral lead is removable after connecting the tab to a prismatic electrochemical cell.

3. The tab of claim 1 wherein the tab is a cathode tab manufactured from a metal from the group consisting of aluminum, nickel, and inconel.

4. The tab of claim 1 wherein the tab is an anode tab manufactured from a metal from the group consisting of copper, nickel, and inconel.

5. The tab of claim 1 wherein the one or more contact strips comprise one or more metal wires.

6. The tab of claim 5 wherein the metal wires are ultrasonically welded to the neutral lead and to the contact lead.

7. The tab of claim 1 wherein the contact lead is L-shaped and the tab is h-shaped.

8. A prismatic electrochemical cell having a cathode end and an anode end, and tabs connected to the cathode end and the anode end, each tab comprising:

(a) a contact lead;

(b) a neutral lead; and

(c) one or more contact strips connecting the contact lead and the neutral lead.

9. The tab of claim 8 wherein the neutral lead is removable.

10. The cell of claim 8 wherein each tab is connected using a metal spray process.

11. The cell of claim 8 wherein the ends of the electrochemical cell and the tabs are pinched with a nipper tool, and are sprayed with a metal spray after being nipped.

12. The cell of claim 11 wherein the nipper tool comprises a nipper blade for deforming the electrochemical cell, a first resilient layer for holding the contact strips in place and a second resilient layer for forming a spray cavity.

13. The cell of claim 10 wherein a spray funnel is used to direct the metal spray.

14. The cell of claim 8 wherein the one or more contact strips comprise one or more wires.

15. The cell of claim 14 wherein the one or more wires are ultrasonically welded to the neutral lead and the contact lead.

16. The cell of claim 14 wherein the tab is heated such that when applied to either the cathode end or anode end the tab will make contact with a current collector.

17. The cell of claim 16 wherein the tab is heated using a tab heater that passes an electrical current through the tab.

18. The cell of claim 17 wherein a metal spray process is used after heating the tab to further connect the tab to the cathode end and anode end.

19. The cell of claim 8 wherein the cathode tab is manufactured from a metal from the group consisting of aluminum, nickel, and inconel.

20. The cell of claim 8 wherein the anode tab is manufactured from a metal from the group consisting of copper, nickel, and inconel.

21. The cell of claim 8 wherein the contact lead is L-shaped and the tab is h-shaped.

22. The cell of claim 8 wherein the anode end comprises an anode active layer comprising lithium and a cathode active layer comprising an electroactive sulfur material.

23. A battery comprising:

(a) a casing; and

(b) one or more electrochemical cells in the casing, wherein each of the cells comprises;

(i) an anode end and a cathode end;

(ii) a tab on the anode end, and a tab on the cathode end wherein each tab comprises;

(A) a contact lead;

(B) a neutral lead; and

(C) one or more contact strips connecting the contact lead and the neutral lead.

24. The battery of claim 23 wherein the cell further comprises an electrolyte.

25. The battery of claim 23 wherein the anode end comprises an anode active layer including lithium and the cathode end comprising a cathode active layer including an electroactive sulfur material.

26. A tab for use on a prismatic electrochemical cell, the tab for providing an electrical contact and comprising:

(a) contact lead; and

(b) two or more contact strips attached to the contact lead.

27. The tab of claim 26 wherein the two or more contact strips comprise two or more metal wires.

28. The tab of claim 26 wherein the two or more metal wires are inserted into an anode end of an electrochemical cell.

29. A prismatic electrochemical cell having a cathode end and an anode end, and tabs connected to the cathode end and the anode end, the anode tab comprising:

(a) a contact lead; and

(b) two or more contact strips attached to the contact lead.

30. The cell of claim 29 wherein the two or more contact strips of the anode tab comprise two or more metal wires.

31. The anode tab of claim 30 wherein the tab is connected to the anode end of the cell by inserting the contact strips of the tab through the end of the cell.