Non-rectangular batteries for portable electronic devices

Patent metadata

Field	Value
Publication number	US-2017125849-A1
Application number	US-201615350719-A
Country	US
Kind code	A1
Filing date	Nov 14, 2016
Priority date	Oct 28, 2011
Publication date	May 4, 2017
Grant date	—

Abstract

The disclosed embodiments provide a battery cell. The battery cell includes a set of layers forming a non-rectangular shape, wherein the set of layers comprises a cathode with an active coating, a separator, and an anode with an active coating. The battery cell also includes a first conductive tab coupled to the cathode and a second conductive tab coupled to the anode. The layers are enclosed in a flexible pouch, and the first and second conductive tabs are extended through seals in the pouch to provide terminals for the battery cell. Furthermore, the non-rectangular shape is created by removing material from one or more of the layers.

First claim

1 .- 25 . (canceled)

26 . A battery cell, comprising:
a set of layers forming a non-rectangular shape, wherein each of the set of layers comprises a cathode with an active coating, a separator, and an anode with an active coating and each of the layers includes at least one rounded corner; a first conductive tab coupled to the cathode; and a second conductive tab coupled to the anode, and the first and second conductive tabs extending from the non-rectangular shape.

27 . The battery cell of claim 26 , wherein the non-rectangular shape is created by removing material from one or more of the layers.

28 . The battery cell of claim 26 , further comprising a flexible pouch enclosing the set of layers.

29 . The battery cell of claim 28 ,
wherein the first and second conductive tabs extend through seals in the flexible pouch to provide terminals for the battery cell.

30 . The battery cell of claim 26 , wherein the layers each have the same non-rectangular shape.

31 . The battery cell of claim 26 , wherein the non-rectangular shape comprises two or more thicknesses.

32 . A method for manufacturing a battery cell, comprising:
obtaining a set of layers for the battery cell, wherein each of the set of layers comprises a cathode with an active coating, a separator, and an anode with an active coating and each of the layers includes at least one rounded corner; coupling a first conductive tab to the cathode; coupling a second conductive tab to the anode; removing material from one or more of the layers to create a non-rectangular shape in the battery cell; and sealing the layers in a pouch to form the battery cell, wherein the pouch is flexible.

33 . The method of claim 32 , further comprising:
performing stacking operations on the set of layers to form a stack.

34 . The method of claim 32 , further comprising:
extending the first and second conductive tabs through seals in the pouch to provide terminals for the battery cell.

35 . The method of claim 32 , further comprising:
stacking the layers to create a bi-cell prior to sealing the layers in the pouch.

36 . The method of claim 32 , further comprising:
winding the layers to create a jelly roll prior to sealing the layers in the pouch.

37 . The method of claim 32 , wherein removing material from one or more of the layers involves:
removing the material from one or more sides of the cathode or the anode to form the non-rectangular shape.

38 . A battery pack, comprising:
a set of battery cells, wherein each of the cells comprises: a set of layers forming a non-rectangular shape, wherein each of the set of layers comprises a cathode with an active coating, a separator, and an anode with an active coating, and each of the layers includes at least one rounded corner; a first conductive tab coupled to the cathode; and a second conductive tab coupled to the anode, the first and second conductive tabs extending from the non-rectangular shape.

39 . The battery pack of claim 38 , wherein the non-rectangular shape is created by removing material from one or more of the layers.

40 . The battery pack of claim 38 , wherein each battery cell further comprises:
a flexible pouch enclosing the layers; and wherein the first and second conductive tabs extend through seals in the flexible pouch to provide terminals for the battery cell.

41 . The battery pack of claim 38 , wherein removing material from one or more of the layers involves:
removing the material from one or more sides of the cathode or the anode to form the non-rectangular shape.

42 . The battery pack of claim 38 , wherein the layers each have the same non-rectangular shape.

43 . The battery pack of claim 38 , wherein the non-rectangular shape comprises two or more thicknesses.

44 . The battery pack of claim 38 , wherein the set of layers is used to create at least one of a jelly roll and a bi-cell.

45 . A portable electronic device, comprising:
a set of components powered by a battery pack; and
the battery pack comprising:
a set of battery cells, wherein each of the battery cells comprises:
a set of layers forming a non-rectangular shape, wherein each of the set of layers comprises a cathode with an active coating, a separator, and an anode with an active coating, and each of the layers includes at least one rounded corner,
a first conductive tab coupled to the cathode; and
a second conductive tab coupled to the anode, and the first and second conductive tabs extending from the non-rectangular shape.

46 . The portable electronic device of claim 45 , wherein the non-rectangular shape is created by removing material from one or more of the layers.

47 . The portable electronic device of claim 45 , wherein each battery cell in the set of battery cells further comprises:
a flexible pouch enclosing the layers; wherein the first and second conductive tabs extend through seals in the flexible pouch to provide terminals for the battery cell.

48 . The portable electronic device of claim 45 , wherein removing material from one or more of the layers involves:
removing the material from one or more sides of the cathode or the anode to form the non-rectangular shape.

49 . The portable electronic device of claim 45 , wherein the layers each have the same non-rectangular shape.

47 . The portable electronic device of claim 45 , wherein the non-rectangular shape comprises two or more thicknesses.

Assignees

• Apple Inc

Inventors

• Bhardwaj Ramesh C
• Raff John
• Mcclure Stephen R
• Wang Erik L
• Hwang Taisup

Classifications

• H01M10/0459

  Cells or batteries with folded separator between plate-like electrodes · CPC title

• H01M10/0436 Primary

  Small-sized flat cells or batteries for portable equipment · CPC title

• H01M2220/30

  Batteries in portable systems, e.g. mobile phone, laptop · CPC title

• H01M10/0585 Primary

  of accumulators having only flat construction elements, i.e. flat positive electrodes, flat negative electrodes and flat separators · CPC title

• H01M10/052

  Li-accumulators · CPC title