Laminar battery system

Patent metadata

Field	Value
Publication number	US-9711770-B2
Application number	US-201314041843-A
Country	US
Kind code	B2
Filing date	Sep 30, 2013
Priority date	Nov 27, 2012
Publication date	Jul 18, 2017
Grant date	Jul 18, 2017

Abstract

A battery system comprises a plurality of substantially planar layers extending over transverse areas. The plurality of layers comprises at least one cathode layer, at least one anode layer, and at least one separator layer therebetween.

First claim

We claim:

1. A battery assembly comprising:
a battery casing; and
a battery core disposed within the battery casing, the battery core comprising at least first and second substantially planar core stack elements, each of the core stack elements comprising:
an anode active material layer;
a cathode active material layer;
a separator layer therebetween; and
an anode collector layer adjacent to the anode active material layer;
wherein:
the battery assembly has a cathode active material layer stacking efficiency of at least about 30% of a thickness of the battery core; and
the thickness of the battery core is less than approximately 100 microns.

2. The battery assembly of claim 1 , wherein each of the core stack elements extends substantially across a transverse area of the battery core.

3. The battery assembly of claim 2 , further comprising a cathode collector layer adjacent and in electrical contact with each of the cathode active material layers, opposite the respective separator layer.

4. The battery assembly of claim 3 , further comprising carbon nanotubes, to which additional lithium ions are attached, extending from the anode active material layer.

5. The battery assembly of claim 1 , wherein the first and second core stack elements have inverted orientations within the battery core.

6. The battery assembly of claim 5 , wherein the cathode active material layers of the first and second core stack elements are adjacent, and further comprising a shared cathode collector layer between the adjacent cathode active material layers.

7. The battery assembly of claim 5 , wherein the anode active material layers of the first and second core stack elements are adjacent and the anode current collector layers of the first and second core stack elements are shared.

8. The battery assembly of claim 5 , wherein the battery assembly has the cathode active material layer stacking efficiency of at least about 40%.

9. The battery assembly of claim 8 , wherein the cathode active material layer is thicker than a separation between the cathode active material layer and the anode active material layer.

10. The battery assembly of claim 1 , wherein the first and second core stack elements have a substantially same orientation within the battery core.

11. The battery assembly of claim 10 , wherein the cathode active material layer of the first core stack element is adjacent the anode active material layer of the second core stack element.

12. The battery assembly of claim 11 , further comprising a spacer layer between the cathode active material layer of the first core stack element and the anode active material layer of the second core stack element.

13. The battery assembly of claim 10 , wherein the battery assembly has the cathode active material layer stacking efficiency of at least about 45%.

14. The battery assembly of claim 13 , wherein the cathode active material layer is thicker than the separator layer.

15. The battery assembly of claim 14 , wherein the cathode active material layer has a thickness of greater than about 20 microns.

16. The battery assembly of claim 1 , further comprising a third core stack element, wherein the first, second and third core stack elements have alternating stacking orientations in the battery core.

17. The battery assembly of claim 1 , further comprising third and fourth core stack elements, wherein the first and fourth core stack elements have substantially inverted stacking orientations in the battery core, with the second and third core stack elements therebetween.

18. The battery assembly of claim 17 , wherein the second and third core stack elements have substantially inverted stacking orientations between the first and fourth core stack elements.

19. A battery assembly comprising:
a battery core having a thickness of less than approximately 100 microns;
a plurality of layers extending across a transverse area of the battery core, the plurality of layers comprising;
at least one cathode active material layer;
at least one anode active material layer;
at least one separator layer therebetween; and
an anode collector layer;

wherein:
the plurality of layers are substantially planar across the transverse area of the battery core, such that the battery core has a substantially laminar and planar and geometry;
a separation between the at least one cathode active material layer and the at least one anode active material layer is thicker than the at least one cathode active material layer; and
a cathode active material layer stacking efficiency of the battery system is at least about 30%.

20. The battery assembly of claim 19 , further comprising a cathode collector layer adjacent to and in electrical contact with the at least one cathode active material layer.

21. The battery assembly of claim 20 , wherein the at least one cathode active material layer comprises a first cathode active material layer, and further comprising a second cathode active material layer adjacent to and in electrical contact with the cathode collector layer, opposite the first cathode active material layer.

22. The battery assembly of claim 19 , further comprising an wherein the anode collector layer is adjacent to and in electrical contact with the at least one anode active material layer.

23. The battery assembly of claim 20 , wherein the at least one anode active material layer comprises a first anode active material layer, and further comprising a second anode active material layer adjacent to and in electrical contact with the cathode collector layer, opposite the first anode active material layer.

24. The battery assembly of claim 19 , further comprising a spacer layer adjacent the at least one anode active material layer.

25. The battery assembly of claim 24 , wherein the at least one cathode active material layer comprises a first cathode active material layer and further comprising a second cathode active material layer adjacent the spacer layer, opposite the at least one anode active material layer.

26. The battery assembly of claim 19 , wherein the cathode active material layer stacking efficiency of the battery system is at least about 30% over substantially the entire transverse area of the battery core, an average of the cathode active material layer stacking efficiency defined by a fraction of a thickness of the battery core.

27. The battery assembly of claim 26 , wherein the cathode active material layer stacking efficiency is at least about 35% over substantially the entire transverse area of the battery core.

28. The battery assembly of claim 27 , wherein the cathode active material layer stacking efficiency is at least about 40% over substantially the entire transverse area of the battery core.

29. The battery assembly of claim 19 , further comprising a battery case disposed about the battery core.

30. A method of forming a core stack for a battery core, the method comprising:
forming an anode active material layer on an anode carrier substrate;
forming a cathode active material layer on a cathode carrier substrate;
forming a separator layer on at least one of the anode active material layer and the cathode active material layer;
forming an anode collector layer adjacent to the anode active material layer; and
assembling the anode active material layer and cathode active material la

Assignees

• Apple Inc

Inventors

• Anastas George V
• Springer Gregory A
• Rector Iii Jack B
• Funamura Joshua R
• Silz Kenneth M

Classifications

• H01M4/0471 Primary

  involving thermal treatment, e.g. firing, sintering, backing particulate active material, thermal decomposition, pyrolysis · CPC title

• H01M50/417

  Polyolefins · CPC title

• H01M10/0562

  Solid materials · CPC title

• Y10T29/49115

  including coating or impregnating · CPC title

• H01M10/052

  Li-accumulators · CPC title