Electrochemical current collector screen designs utilizing ultrasonic welding

Patent metadata

Field	Value
Publication number	US-2016155996-A1
Application number	US-201615016988-A
Country	US
Kind code	A1
Filing date	Feb 5, 2016
Priority date	Sep 14, 2012
Publication date	Jun 2, 2016
Grant date	—

Abstract

An electrochemical cell comprising an electrode assembly having a plurality of cathodes in which the plurality of cathodes is electrically connected together at a connection tab junction is disclosed. The junction preferably comprises a plurality of cathode connection tabs that are folded over each other to construct a junction that is mechanically and electrically robust. The junction is comprised of a plurality of connection tabs that each extend from a cathode. Each of the respective tabs is folded over each other to form a compact electrode junction having redundant connections. An elongated lead extends from the junction to provide an electrical connection to the plurality of cathodes. The junction is welded together such as by a laser, resistance or ultrasonic weld joint. The cathode junction is suitable for either primary or secondary cells, particularly those powering implantable biomedical devices.

First claim

What is claimed is:

1 . An electrochemical cell, the cell comprising:
a) a casing; b) an electrode assembly contained within the casing, the electrode assembly comprising:
i) a plurality of cathodes, each cathode composed of an active cathode material, wherein each cathode comprises a cathode connection tab that extends outwardly therefrom;
ii) an anode composed of an active anode material having a plurality of folds at spaced intervals along a length thereof, a first anode connection tab extending outwardly from within the anode, wherein at least one of the plurality of cathodes is received within one of the folds of the anode, a separator membrane residing between the anode and the cathode;
iii) a current collector, composed of a current collector metal, incorporated with a portion of at least one of the active anode or cathode materials;
iv) wherein the plurality of cathode connection tabs are folded over each other thereby creating a cathode connection tab junction, a terminal lead electrically connected to the cathode tab junction; and
c) an electrolyte contained within the casing to activate the electrode assembly.

2 . The electrochemical cell of claim 1 further comprising a terminal pin that extends from a proximal terminal pin end to a distal terminal pin end insulated from the casing by a glass-to-metal seal that is supported by a casing lid, wherein the proximal terminal pin end is positioned within the casing electrically connected to the connection tab junction and the distal terminal pin end extends outwardly from the casing.

3 . The electrochemical cell of claim 1 wherein the anode is formed in a serpentine-like shape that weaves between each of the plurality of cathodes.

4 . The electrochemical cell of claim wherein the first anode connection tab is positioned in electrical contact with an interior surface of the casing.

5 . The electrochemical cell of claim 1 wherein each of the cathode connection tabs have spaced apart first and second folds positioned along a length of the respective connection tabs, the first fold positioned proximate the cathode, wherein a first tab portion that extends distal of the first fold is oriented about perpendicular to the first fold, and wherein a second tab portion that extends distal of the second fold at least partially extends over the first tab portion and in electrical contact therebetween.

6 . The electrochemical cell of claim 1 wherein the active anode material comprises lithium, lithium silver, lithium aluminum, lithium boron, lithium silver boron, carbon, and combinations thereof.

7 . The electrochemical cell of claim 1 wherein the current collector comprises a material selected from the group consisting of titanium, aluminum, nickel, and stainless steel.

8 . The electrochemical cell of claim 1 wherein the casing comprises a material selected from the group consisting of titanium, nickel, and stainless steel.

9 . The electrochemical cell of claim 1 wherein the active anode material is supported on an inside surface of the casing.

10 . The electrochemical cell of claim 1 wherein the active anode material is supported on a portion of a surface of an inside surface of a casing lid.

11 . The electrochemical cell of claim 1 wherein the electrolyte comprises a nonaqueous solvent and an ionically conductive salt dissolved therein.

12 . The electrochemical cell of claim 1 wherein each of the plurality of the cathodes is of a plate-like structure.

13 . The electrochemical cell of claim 1 wherein a weld joint joins the plurality of folded cathode connection tabs together at the junction.

14 . An electrochemical cell, comprising:
a) a casing of electrically conductive material; b) an electrode assembly comprising first and second opposite polarity electrodes housed inside the casing in electrochemical association with each other and having a separator disposed therebetween, wherein each of the electrodes includes a current collector; c) an electrolyte activating the first and second electrodes; d) the first electrode having a serpentine configuration comprising a plurality of successive folds, the second opposite polarity electrodes positioned within the first electrode folds, wherein the second electrodes comprising a second electrode tab that outwardly extends therefrom, and wherein the first electrode comprises a first electrode tab that outwardly extends from within the first electrode; e) wherein the second electrode tabs are folded together thereby forming a second electrode tab junction, a lead electrically connected to the second electrode junction and wherein the first electrode tab is electrically connected to an interior surface of the conductive casing; and f) a terminal having spaced apart proximal and distal terminal ends insulated from the casing, wherein the proximal terminal end is electrically connected to the second electrode tab junction and the distal terminal end outwardly ends from the casing.

15 . The electrochemical cell of claim 14 wherein each of the second electrode tabs have spaced apart first and second folds positioned along a length of the respective tabs, the first fold positioned proximate the second electrode, wherein a first tab portion extending distal of the first fold is oriented about perpendicular to the first fold, and wherein a second tab portion that extends distal of the second fold at least partially extends over the first tab portion and in electrical contact therebetween.

16 . The electrochemical cell of claim 14 wherein the first electrode is composed of an active electrode material selected from the group consisting of lithium, lithium silver, lithium aluminum, lithium boron, lithium silver boron, carbon, and combinations thereof.

17 . The electrochemical cell of claim 14 wherein the first or second electrode current collector is composed of a material selected from the group consisting of titanium, aluminum, nickel, and stainless steel.

18 . The electrochemical cell of claim 14 wherein the casing comprises a material selected from the group consisting of titanium, nickel, and stainless steel.

19 . The electrochemical cell of claim 14 wherein the electrolyte comprises a nonaqueous solvent and an ionically conductive salt dissolved therein.

20 . The electrochemical cell of claim 14 wherein each of the plurality of second electrodes is of a plate-like structure.

21 . The electrochemical cell of claim 14 wherein a weld joint joins the plurality of folded second electrode tabs together at the junction.

22 . A method of constructing an electrochemical cell, the method comprising the following steps:
a) providing a casing and a lid; b) providing an electrode assembly, the electrode assembly comprising:
i) a plurality of cathodes, each cathode composed of an active cathode material, wherein each cathode comprises a cathode connection tab that extends outwardly from within the cathode;
ii) an anode composed of an active anode material having a plurality of folds at spaced intervals along a length thereof, a first anode connection tab extending outwardly from within the anode, wherein at least one of the plurality of cathodes is received within one of the folds of the anode, and a separator membrane residing between the anode and the cathode; and
c) folding the plurality of cathode connection tabs over each other and positioning a terminal lead within the folds of the cathode connection tabs; d) joining the plurality

Assignees

• Greatbatch Ltd

Inventors

• Dai Xiangyang

Classifications

• H01M4/661 Primary

  Metal or alloys, e.g. alloy coatings (H01M4/669 take precedence) · CPC title

• H01M50/566

  by welding, soldering or brazing · CPC title

• H01M50/176

  for prismatic or rectangular cells (H01M50/181 takes precedence) · CPC title

• H01M50/533

  characterised by the shape of the leads or tabs · CPC title

• H01M50/553

  Terminals adapted for prismatic, pouch or rectangular cells · CPC title