Merged battery cell with interleaved electrodes
09564669 ยท 2017-02-07
Assignee
Inventors
Cpc classification
H01M10/0587
ELECTRICITY
Y02P70/50
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
Y10T29/49115
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
H01M4/133
ELECTRICITY
Y10T29/4911
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
H01M10/0585
ELECTRICITY
Y02E60/10
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
H01M4/131
ELECTRICITY
H01G11/72
ELECTRICITY
Y02E60/13
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
H01M10/0525
ELECTRICITY
Y10T29/49108
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
H01M10/654
ELECTRICITY
H01G11/18
ELECTRICITY
International classification
H01M10/654
ELECTRICITY
H01M10/0525
ELECTRICITY
H01G11/72
ELECTRICITY
H01M10/0585
ELECTRICITY
Abstract
A battery having the electrodes of multiple battery cell types are interleaved to prevent thermal runaway by cooling a shorted region between electrodes. The electrodes of each of the battery cell types with a first polarity share a pair of the common electrodes having a second polarity. The electrodes of the multiple battery cell types and the multiple common electrodes are interleaved such that if the electrodes of the multiple battery cell types and the adjacent common electrodes of one or more battery cell types short together, the current within the shorted battery cells is sufficiently small to prevent thermal runaway and the electrodes of the adjacent cells of the other battery cell types of the first polarity and the common electrodes of the second polarity not having short circuits provide heat sinking for the heat generated by the short circuit to prevent thermal runaway.
Claims
1. A method for forming a battery having multiple merged battery cells structured to prevent thermal runaway by cooling a shorted region between electrodes comprises the steps of: forming a plurality of electrodes of a first polarity for each of the multiple battery cells; forming a connection tab placed at a unique location on each of the plurality of electrodes for each battery cell of the multiple battery cells; forming a plurality of common electrodes of a second polarity; forming a connection tab on each common electrode at another location unique from the connection tabs of each of the multiple battery cells; and interleaving electrodes of the multiple battery cells and the multiple common electrodes to form a merged stack of the multiple battery cells such that when any of the electrodes of the multiple battery cells and the adjacent common electrodes short together, the current within the shorted battery cells is sufficiently small to prevent thermal runaway and the electrodes of the adjacent cells of the other battery cells of the first polarity and the common electrodes of the second polarity not having short circuits provide heat sinking for the heat generated by the short circuit to further prevent thermal runaway.
2. The method for forming a battery method for forming a battery claim 1 wherein the step of forming the electrodes of each battery cell of the multiple battery cells and the step of forming the common electrodes comprises the steps of: forming a first metal film to the shape of the each of the electrodes of the each battery cell of the multiple battery cells; forming a second metal film to the shape of the common electrodes; placing the first metal films of each of the electrodes of the each battery cells of the multiple battery cells in proximity with a first separator; placing the second metal films of each of the common electrodes in proximity with a second separator; coating the first metal film on both sides with a first electrochemically active material; and coating the second metal film on both sides with a second electrochemically active material.
3. The method for forming a battery claim 2 wherein the first metal film is aluminum.
4. The method for forming a battery of claim 2 wherein the second metal film is copper.
5. The method for forming a battery of claim 2 wherein the first electrochemically active material is graphite.
6. The method for forming a battery of claim 2 wherein the second electrochemically active material is lithium metal oxide.
7. The method for forming a battery of claim 2 wherein the electrodes of a first polarity for each of the multiple battery cells placed at the exterior surface have the electrochemically active material placed on one side of the first metal film placed toward the interior of the battery.
8. The method for forming a battery of claim 2 wherein the common electrodes placed at the exterior surface have the electrochemically active material placed on one side of the second metal film placed toward the interior of the battery.
9. The method for forming a battery of claim 1 further comprising the step assembling the battery by the steps of: interleaving each of the plurality of the electrodes of each of the plurality of battery cells of the first polarity; interleaving one of the plurality of common electrodes between each of the interleaved plurality of the electrodes of the each of the plurality of battery cells of the first polarity; placing a first half electrode having an active electrode material coating the first half electrode at a first side of the interleaved electrodes with the active electrode material adjacent to one of the interleaved electrodes; placing a second half electrode having the active electrode material coating the second half electrode at a second side of the interleaved electrodes with the active electrode material adjacent to another of the interleaved electrodes; compressing the interleaved electrodes of the first polarity of each cell of the multiple battery cells and the common electrodes; placing the interleaved electrodes of the first polarity of each cell of the multiple battery cells and the common electrodes in a shell or pouch; placing an electrolyte in the shell or pouch to immerse the interleaved electrodes of the first polarity of each battery cell of the plurality of battery cells and the common electrodes; sealing the shell or pouch; connecting with the connective tabs for each electrode of the first polarity of each of the plurality of battery cells to one of a plurality of terminals; and connecting the connective tabs for the common electrodes to a common terminal.
10. The method for forming a battery of claim 1 wherein the electrodes of the first polarity of each of the plurality of battery cells have a differing chemistry between the battery cells.
11. The method for forming a battery of claim 1 further comprising the step of connecting the interleaved plurality of battery cells in a series configuration.
12. The method of for forming a battery of claim 1 further comprising the step of connecting the interleaved plurality of battery cells in a parallel configuration.
13. The method for forming a battery of claim 1 further comprising the step of connecting the merged battery cells in a series-parallel configuration.
14. The method for forming a battery of claim 1 further comprising the step of protecting interleaved plurality of battery cells with a current limiting device.
15. The method for forming a battery claim 14 wherein the current limiting device is a fuse, a thermal cut-off device, a positive thermal coefficient device, a metal-oxide-semiconductor field effect transistor (MOSFET), or other apparatus capable of restricting the excess current flow through the interleaved electrodes of the first polarity of each battery cell of the plurality of battery cells and the common electrodes in an over-current event.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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DETAILED DESCRIPTION
(11) A high capacity battery often consists of a multiple of low capacity battery cells connected in parallel. There is a strong desire to minimize the number of cells, for cost reduction, ease of assembly, and packing efficiency improvement. However this will require an increase in the capacity of individual cells. Unfortunately, the capacity of individual cells is limited by stability of the cell. This is true for all types of charge accumulators (battery cells and capacitors), but especially serious for lithium ion battery cells.
(12) A battery, the cell structure of a battery and a method of assembly of battery cells that embody the principles of this disclosure effectively prevents thermal runaway by limiting a short circuit current, and by providing a heat sinking capacity for cooling the location of the short circuit. This is accomplished by merging at least two different battery cell types in a stack, sharing electrodes of one polarity and interleaving electrodes of another polarity. A stack of battery cell types includes common electrodes of one type and may be either positive or negative electrodes. In some embodiments the common electrodes are positive electrodes and the stack further includes multiple types of negative electrodes. The common electrodes have connective tabs located in one location and the each of the multiple types of electrodes have connective electrodes have connective tabs located in unique locations for each of the types of electrodes separated from the connective tabs of the others of the multiple types of electrodes and the common electrodes.
(13) In some embodiments, some electrodes may have more than one connective tab to achieve low electrical resistance, and more uniform current distribution. On the other hand, due to limited space, and for the ease of production, the number of tabs should be minimized. Furthermore, it is sometimes desirable to have the aluminum tab of the cathode acting as a fuse. In this case a cathode is likely to have one tab only. Regardless of the number of tabs in each type of electrode, tabs of different types of electrodes should be situated such that they do not interfere with each other. In various embodiments, the connective tabs are located such that one of the types of electrodes are formed from another type of electrode of the same polarity by a mere rotation. Since electrodes on both ends of the stack need to be symmetrical to and congruent with each other, it follows that they are preferably of the common type, and that tabs of the common type should be symmetrically located.
(14) In some embodiments, the connective tabs of the common electrodes are located at one edge of the common electrodes and the connective tabs of the multiple types of electrodes are formed at locations on other edges of the multiple electrodes. In various embodiments, the connective tabs are formed at the edge opposite of the connective tabs of the common electrodes such that the terminal of the common electrodes is at one end of the battery and the terminals of the multiple electrodes is at an opposing end of the battery.
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(16) Each of the interior common electrodes 510b is placed adjacent to one of the electrodes 515 520 of the multiple battery cell types (type A and type B in the present embodiment) and separated by a separator 535 of
(17) The stack 500 of the common electrodes 510a and 510b, the battery cell type A electrodes 515, and battery cell type B electrodes 520 are aligned and compressed as shown in
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(19) It should be noted that the embodiment as shown in
(20) An electrode stack of a first number (M) of merged cells 510a, 510b, 515 and 520 consists of a second number (T) of types of electrodes (515 and 520 in the example of
(21) It is known by one skilled in the art that there are other methods of stacking the electrodes 510a, 510b, 515 and 520. The method of stack construction described is exemplary and the it would be obvious to one skilled in the art to incorporate the merging of multiple battery cell types of the present disclosure into the other methods of stacking to be in keeping with the principles of the present disclosure.
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(24) Each of the common electrodes 710 is placed adjacent to one of the electrodes 715a, 715b, 720a, and 720b of the multiple battery cell types (type A and type B in the present embodiment). The battery cell type A electrodes 715a and 715b and battery cell type B electrodes 720a, and 720b are formed of a metal film such as aluminum in close proximity with a separator. The aluminum film is coated with an electrochemically active material such as lithium metal oxide (lithium cobalt oxide and lithium magnesium aluminum oxide). Each of the battery cell type A electrodes 715a and 715b have a connective tab 716 placed at a unique location aligned at a second edge opposite the first edge of the common electrodes 710 to facilitate connecting the connective tabs 716 together and to an external terminal (not shown). Similarly, each of the battery cell type B electrodes 720a, and 720b have a connective tab 721 placed at a unique location at the second edge opposite the first edge of the common electrodes 710 and aligned to facilitate connecting the connective tabs 721 together and to an external terminal (not shown). The battery cell type A electrode 715a and the battery cell type B electrode 720b are placed at the exterior ends of the stack of electrodes 700 are coated with the electrochemically active material on the one side facing the interior of the stack 700 of the electrodes. The exterior surfaces of the battery cell type A electrode 715a and the battery cell type B electrode 720b do not require coating, because these two surfaces are not facing electrodes 710 of opposite polarity and do not participate in the electrochemical reaction. The battery cell type A electrode 715b and the battery cell type B electrode 720a within the interior of the stack 700 of electrodes are coated on two sides of each of the common electrodes 710b.
(25) In some embodiments, the connective tabs 716 of the battery cell type A electrodes 715a and 715b and the connective tabs 721 of the battery cell type B electrodes 720a, and 720b are placed in mirroring locations. The battery cell type A electrodes 715a and 715b and the battery cell type B electrodes 720a, and 720b are commonly manufactured with the battery cell type B electrodes 720a, and 720b being the battery cell type A electrodes 715a and 715b rotated horizontally in the illustration. This permits the two connective tabs 716 and 721 to be sufficiently separated to have two separate cell connection. In
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(27) It should be noted that while the method is illustrating electrodes of two battery cell types of the first polarity, any number of battery cell types of the first polarity may be formed. The connection tabs for each of the electrodes of the multiple battery cell types must be placed to avoid contact between the electrodes of each battery cell type. In various embodiments, the two battery cell types may have a common structure and differ only in horizontal orientation.
(28) The electrodes of each of the first and second battery cell types are formed of a metal film such as aluminum in close proximity with a separator. The common electrodes are formed of a metal film such as copper in close proximity with a separator. The metal film of the first battery cell type, second battery cell type, and common electrodes placed in the interior of the battery is coated on both sides with an electrochemically active material. The electrodes placed at the exterior surface have the electrochemically active material placed on one side of the electrode place toward the interior of the battery. In the embodiments as shown above, the exterior electrodes are the common electrodes. The electrochemically active material for the common electrodes is graphite and the electrochemically active material for the electrodes of the first and second battery cell types is a lithium metal oxide (lithium cobalt oxide or lithium magnesium aluminum oxide).
(29) The electrodes of each of the first and second battery cell types are interleaved (Box 815) with a common electrode placed between each of the electrodes of each of the first and second battery cell types. The stack of the interleaved electrodes is compressed (Box 820) to form a battery unit. The battery unit of the interleaved electrodes is placed (Box 825) in a containment shell or pouch. The containment shell may be a metal shell such as stainless steel or a non-reactive plastic. In other embodiments, the interleaved stack of electrodes is placed in a plastic pouch that is sealed. The containment shell or the pouch is filled with an electrolyte to immerse the electrodes. The connection tabs of the electrodes of the first battery cell type are connected (Box 830) together and the connection tabs of the electrodes of the second battery cell type are connected (Box 835) together. The connection tabs of the common electrodes are connected together (Box 840). The connection tabs of each of the common electrodes are connected together.
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(35) While the embodiments shown illustrate a lithium ion battery structure, other charge accumulation devices such capacitors and other battery cell types may have multiple battery cell types and common electrodes interleaved to prevent large short circuit current and provide thermal dissipation to prevent thermal runaway. The other charge accumulators embody the principles of the present disclosure.
(36) While this disclosure has been particularly shown and described with reference to the preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made without departing from the spirit and scope of the disclosure.