BATTERY COMPRISING ELECTRODE WITH LASER-SINTERED MATERIAL AND AT LEAST ONE HUNDRED ELECTRODE EXTENSIONS

Abstract

Instant invention comprises an electrode configured with laser-sintered coating materials, said electrode further comprised of at least one hundred extensions. Said electrode comprises a jelly roll of battery materials wherein an end plate in wound jelly roll comprises said at least one hundred extensions in shingle-style overlaps to extensions of same electrode. A battery comprised of said jelly roll of battery materials comprises improved capacity due to laser sintering, and further comprises improved useful life by large area of electrical connections to external circuit enabled by said electrode extensions configured in end plate as shingle-style overlaps. In a preferred embodiment, laser-sintered materials comprise in anode, selection from a group consisting of Li, C, Si, Mg, Cu, Ni, Al, Ti, Sn and the arbitrary combinations thereof; and in cathode, selection from a group consisting of lithium-cobalt-based composites, LiFePO.sub.4-based composites, lithium LiMnPO.sub.4-based composites, lithium-manganese-based composites, lithium-nickel-based composites, lithium-cobalt-nickel-manganese-based composites, and the arbitrary combinations thereof.

Claims

1-20. (canceled)

21. A cylindrical battery comprising at least one electrode comprised of laser-sintered materials, said electrode comprising extensions compactly assembled within end plate of jelly roll of battery materials, said end plate configured whereby at least four of said electrode extensions receiving each shingle style face-to-face overlaps comprising at least four other extensions each of said at least one electrode.

22. The at least one electrode of claim 21 further comprising electrical contact within said end plate overlaps, said electrical contact enabling transit with respect to external circuit for at least plurality of electrons interactive with at least one laser sintered active particle of said electrode.

23. The cylindrical battery of claim 22 comprising top and bottom end plates each comprising peripheral tabs securing end plate overlaps of electrode extensions against unraveling.

24. The cylindrical battery of claim 23 wherein sintered materials as to battery capacity, and plurality of extension overlaps as to smooth delivery of power to external circuit, mutually reinforce battery performance.

25. A method for cylindrical battery to provide smooth delivery of power to an external circuit, comprising step of configuring cylindrical battery to comprise at least one electrode comprised of extensions compactly assembled within end plate of jelly roll of battery materials, said end plate configured whereby at least four of said electrode extensions receiving each shingle style face-to-face overlaps comprising at least four other extensions each of said at least one electrode.

26. The method of claim 25 further comprising step of comprising said at least one electrode of laser-sintered materials providing plurality of electrons in transit via said overlaps.

27. The method of claim 26 further comprising step of said laser-sintered materials comprising in anode, selection from a group consisting of Li, C, Si, Mg, Cu, Ni, Al, Ti, Sn and the arbitrary combinations thereof.

28. The method of claim 27 further comprising step of said laser-sintered materials comprising in cathode, selection from a group consisting of lithium-cobalt-based composites, LiFePO.sub.4-based composites, lithium LiMnPO.sub.4-based composites, lithium-manganese-based composites, lithium-nickel-based composites, lithium-cobalt-nickel-manganese-based composites, magnesium (Mg)/nickel (Ni) alloy, and the arbitrary combinations thereof.

29. The method of claim 28 further comprising step of configuring each of top and bottom end plates of said jelly roll of battery materials as comprising each at least four electrode extensions receiving each shingle style face-to-face overlaps comprising at least four other extensions each within said top and said bottom end plate.

30. A system for enabling battery capacity and battery electron pathways, said system comprising: jelly roll of battery materials comprised of at least one electrode comprising laser-sintered materials, and further comprising said electrode of at least one hundred electrode extensions.

31. The system of claim 30 further comprising said laser-sintered materials of metal selected from a group consisting of Ti, Au, Ag, Fe, Al, Cu, and the combinations thereof.

32. The system of claim 31 further comprising said laser-sintered materials in anode comprised of selection from a group consisting of Li, C, Si, Mg, Cu, Ni, Al, Ti, Sn and the arbitrary combinations thereof.

33. The system of claim 32 further comprising laser-sintered materials in cathode comprising selection from a group consisting of lithium-cobalt-based composites, LiFePO.sub.4-based composites, lithium LiMnPO.sub.4-based composites, lithium-manganese-based composites, lithium-nickel-based composites, lithium-cobalt-nickel-manganese-based composites, and the arbitrary combinations thereof.

34. The system of claim 33 further comprising battery comprising said jelly roll wherein end plate of jelly roll comprises said at least one hundred extensions in shingle-style overlaps, and further comprises at least ten tabs securing said jelly roll end plate against unraveling.

35. The system of claim 34 wherein said laser-sintered materials engage within electrode conductive layer to enablement of electrical power as transmitted through shingled overlaps of end plate extensions electrical connections of said electrode.

Description

BRIEF DESCRIPTION OF THE FIGURES

[0016] Other features and advantages of the present invention will become apparent when the following detailed description is read in conjunction with the accompanying drawings, in which:

[0017] FIG. 1 is a schematic illustrating details of a preferred embodiment.

[0018] FIG. 2 is a schematic illustrating details of a preferred embodiment.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[0019] In FIG. 1, a preferred embodiment of instant invention is illustrated wherein an electrode 101 is illustrated with dividing line to indicate a longer electrode is typical for instant invention. It is understood that electrode comprises a plurality of electrode extensions 103. The divided electrode schematic comprises in illustration ten extensions, which are understood to represent the at least 100 extensions of typical electrode of instant invention.

[0020] A layer of materials 105 is present on lower aspect of said electrode 101. Said materials coat electrode 101 and are subjected, during manufacture, to laser sintering, as is well known in the art (please refer to U.S. Pat. No. 10,644,305 cited above for details).

[0021] It is understood that after sintering, jelly roll is assembled and wound about a central axis in manner well known in the art. It is understood that jelly roll is comprised after winding, into battery case. It is understood that battery case is attached to external circuit in the standard manner. Said battery, in service, is understood to provide power via electrical connection to an external circuit. It is understood that active materials in the battery enable the said providing of power.

[0022] In a preferred embodiment, said laser-sintered material comprises metal selected from a group consisting of Ti, Au, Ag, Fe, Al, Cu, and the combinations thereof. In a preferred embodiment, said laser-sintered materials comprise active particles comprising an anode, said material selected from a group consisting of Li, C, Si, Mg, Cu, Ni, Al, Ti, Sn and the arbitrary combinations thereof. In a preferred embodiment, active particles comprise a cathode material selected from a group consisting of lithium-cobalt-based composites, LiFePO.sub.4-based composites, lithium LiMnPO.sub.4-based composites, lithium-manganese-based composites, lithium-nickel-based composites, lithium-cobalt-nickel-manganese-based composites, and the arbitrary combinations thereof.

[0023] In a preferred embodiment, the battery comprised of instant invention electrode is simultaneously enabled when in service to external circuit, to improved charge capacity and improved electrical connection to external circuit. It is understood that the capacity is improved by sintered materials, and that the electrical connection is improved by the electrode extensions in overlap. It is understood that together, these factors mutually reinforce the performance factors of the battery.

[0024] In FIG. 2, a preferred embodiment of instant invention is illustrated wherein an end plate 201 of jelly roll of battery materials is shown. Said jelly roll is understood to comprise at least one electrode which comprises laser-sintered materials. Said jelly roll further comprises a plurality of electrode extensions to comprise said laser-sintered-materials-comprised electrode.

[0025] Ends of electrode extensions 201 are shown in 4 groups of overlapped extensions across the expanse of the end plate, viewed in perspective from above side of jelly roll. It is understood that each extension of electrode comprises a front face and a back face. It is understood that in FIG. 2, top edges of overlapped electrode extensions are viewed in top/side of jelly roll perspective view.

[0026] The extensions of this electrode of jelly roll here wound and in perspective view of end plate number one hundred or more in instant invention. But per this schematic, the one hundred or more extensions are represented by said 4 groups at 203. The details of tight overlap of face of one extension shingle-overlapped onto face of adjacent extension are shown 204.

[0027] The tabs 202 are typically disposed as a plurality of tabs all around the periphery of the end plate, but here the full periphery of tabs is represented by 4 tabs. The tabs secure said end plate against unraveling. The extensions of electrode are closely approximated, within the battery case, during battery operations, thus enabling secure electrical connection to external circuit.

[0028] The enablement to safe, efficient operations and longer useful battery life comprised by laser-sintered material disclosed herein is mutual reinforcing to that benefit derived from the secure electrical connections enabled by the electrode extensions as end plate configured.

[0029] The mutual benefits of laser sintering of electrode materials and overlaps of electrode extensions comprise the following: Due to the laser sintering, the active particles can be more tightly engaged with the conductive layer, thus the capacity of battery to hold a charge is improved. Meanwhile, such increased charge capacity is more efficiently shared as smoothly delivered power to the needs of the external circuit, such smooth delivery of power enabled by battery use of secure electrical connections comprised as multiple electron paths provided by overlapped extensions of the electrode at the end plate.

[0030] Although the invention has been described in considerable detail in language specific to structural features, and or method acts, it is to be understood that the invention defined in the appended claims is not necessarily limited to the specific features or acts described. Rather, the specific features and acts are disclosed as exemplary preferred forms of implementing the claimed invention. Stated otherwise, it is to be understood that the phraseology and terminology employed herein, as well as the abstract, are for the purpose of description and should not be regarded as limiting. Therefore, while exemplary illustrative embodiments of the invention have been described, numerous variations and alternative embodiments will occur to those skilled in the art. Such variations and alternate embodiments are contemplated and can be made without departing from the spirit and scope of the invention.

[0031] A portion of the disclosure of this patent document contains material which is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, as it appears in the Patent and Trademark Office patent file or records, but otherwise reserves all copyright rights whatsoever.