US20080010816A1 - Headspace insulator for electrochemical cells - Google Patents
Headspace insulator for electrochemical cells Download PDFInfo
- Publication number
- US20080010816A1 US20080010816A1 US11/861,344 US86134407A US2008010816A1 US 20080010816 A1 US20080010816 A1 US 20080010816A1 US 86134407 A US86134407 A US 86134407A US 2008010816 A1 US2008010816 A1 US 2008010816A1
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- US
- United States
- Prior art keywords
- battery
- electrode
- insulator
- pin
- feedthrough
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
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Images
Classifications
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M6/00—Primary cells; Manufacture thereof
- H01M6/14—Cells with non-aqueous electrolyte
- H01M6/16—Cells with non-aqueous electrolyte with organic electrolyte
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
- H01M50/10—Primary casings; Jackets or wrappings
- H01M50/172—Arrangements of electric connectors penetrating the casing
- H01M50/174—Arrangements of electric connectors penetrating the casing adapted for the shape of the cells
- H01M50/176—Arrangements of electric connectors penetrating the casing adapted for the shape of the cells for prismatic or rectangular cells
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
- H01M50/50—Current conducting connections for cells or batteries
- H01M50/528—Fixed electrical connections, i.e. not intended for disconnection
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
- H01M50/60—Arrangements or processes for filling or topping-up with liquids; Arrangements or processes for draining liquids from casings
- H01M50/609—Arrangements or processes for filling with liquid, e.g. electrolytes
- H01M50/627—Filling ports
- H01M50/636—Closing or sealing filling ports, e.g. using lids
-
- Y—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
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
- Y02P70/50—Manufacturing or production processes characterised by the final manufactured product
-
- Y—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
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
- Y10T29/49108—Electric battery cell making
-
- Y—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
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
- Y10T29/49108—Electric battery cell making
- Y10T29/4911—Electric battery cell making including sealing
-
- Y—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
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
- Y10T29/49108—Electric battery cell making
- Y10T29/49114—Electric battery cell making including adhesively bonding
Definitions
- a battery in embodiments of the invention may include one or more of the following features: (a) an electrode assembly having a second electrode tab and a first electrode tab, (b) a battery case having the electrode assembly within the battery case, (c) a battery cover having a feedthrough, the battery cover being coupled to the battery case, (d) a headspace insulator having a receiving area, (e) a feedthrough assembly having a ferrule, feedthrough pin, and insulating member, the feedthrough pin having a distal end locked into the receiving area and coupled to the second electrode tab, (f) a weld bracket coupled to the battery cover, the weld bracket being coupled to the first electrode tab, (g) a second electrode opening to accept the second electrode tab, and a first electrode opening to accept the first electrode tab, (h) a case liner, (i) a coil insulator having slits, the coil insulator and the case liner enclosing the electrode assembly with the second electrode tab and the first electrode tab extending through the s
- Methods of manufacturing a battery for an IMD may include one or more of the following steps: (a) placing a case liner and a coil insulator over an electrode assembly, (b) coupling a weld bracket to a battery cover, (c) coupling a headspace insulator to the battery cover, (d) bending the feedthrough pin, (e) locking a distal end of the feedthrough pin into a receiving area in the headspace insulator, (f) aligning the headspace insulator with the electrode assembly so a second electrode tab on the electrode assembly is accepted within a second electrode opening in the headspace insulator and a first electrode tab on the electrode assembly is accepted within a first electrode opening in the headspace insulator, (g) coupling the second electrode tab and the distal end of the feedthrough pin, (h) coupling the first electrode tab and the weld bracket, (i) placing the electrode assembly within the battery case, (j) coupling the battery cover to the battery case, (k) filling the battery case with an
- FIG. 2 is a cutaway perspective view of a battery case, electrode assembly, case liner, coil insulator, battery cover, and a headspace insulator in an embodiment according to the present invention.
- FIG. 3 is a cutaway perspective view of the electrode assembly as shown in FIG. 2 .
- FIGS. 2 and 4 also depict battery cover 46 and a headspace insulator 62 along with case 42 and electrode assembly 44 .
- cover 46 is comprised of medical grade titanium to provide a strong and reliable weld creating a hermetic seal with battery case 42 .
- cover 46 could be made of any type of material as long as the material was electrochemically compatible.
- Illustrated battery cover 46 includes a feedthrough aperture 64 through which feedthrough assembly 68 is inserted.
- Feedthrough assembly contains a ferrule 67 , a insulating member 65 , and a feedthrough pin 66 .
- Feedthrough pin 66 is comprised of niobium; however, any conductive material could be utilized without departing from the spirit of the invention.
- Niobium is generally chosen for its low resistivity, its material compatibility during welding with titanium, and its coefficient of expansion when heated.
- Niobium and titanium are compatible metals, meaning when they are welded together a strong reliable weld is created.
Landscapes
- Chemical & Material Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Electrochemistry (AREA)
- General Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Sealing Battery Cases Or Jackets (AREA)
Abstract
A headspace insulator for a battery cell operatively coupled to circuitry within an implantable medical device in including one or more of the following: (a) a body of electrically and thermally insulating material disposed between a battery electrode assembly and a battery cover, (b) a receiving area within the body that receives and isolates a battery feedthrough pin, (c) an indentation within the receiving area retaining the feedthrough pin within the receiving area, (d) a raised portion coupled to a battery cover providing an air gap between the cover and the headspace insulator near case-to-cover weld areas, (e) a feedthrough aperture adapted to receive a feedthrough assembly, (f) a pin aperture that receives the feedthrough pin, (g) a fillport aperture for electrolyte fluid flow through the headspace insulator, and (h) a slot that locates a battery weld bracket and isolates it from the feedthrough pin.
Description
- This application is a divisional of application Ser. No. 10/723,317, filed Nov. 26, 2003, now allowed.
- The present invention relates to the field of power sources such as primary batteries, capacitors and rechargeable batteries for devices such as an implantable medical device (IMD). More particularly, the present invention relates to an improved headspace insulator for an electrochemical cell adapted to be operatively coupled to electronic circuitry within an IMD. Furthermore, the present invention relates to electrochemical cells comprising a novel headspace insulator and a method of fabricating an electrochemical cell incorporating said headspace insulator.
- Implantable medical devices are used to treat patients suffering from a variety of conditions. An example of an IMD include implantable pulse generators (e.g., a cardiac pacemaker) and implantable cardioverter-defibrillators (ICDs), which are electronic medical devices that monitor the electrical activity of the heart and provide electrical stimulation to one or more of the heart chambers, when necessary. For example, a pacemaker senses an arrhythmia, i.e., a disturbance in heart rhythm, and provides appropriate electrical stimulation pulses, at a controlled rate, to selected chambers of the heart in order to correct the arrhythmia and restore the proper heart rhythm. The types of arrhythmias that may be detected and corrected by pacemakers include bradycardias, which are unusually slow heart rates, and certain tachycardias, which are unusually fast heart rates.
- Implantable cardioverter-defibrillators also detect arrhythmias and provide appropriate electrical stimulation pulses to selected chambers of the heart to correct the abnormal heart rate. In contrast to pacemakers, however, an ICD can also provide more power. This is because ICDs are designed to correct fibrillation, which is a rapid, unsynchronized quivering of one or more heart chambers, and severe tachycardia, where the heartbeats are very fast but coordinated. To correct such arrhythmias, an ICD delivers a low, moderate, or high-energy shock to the heart.
- In order to perform their pacing and/or cardioverting-defibrillating functions, pacemakers and ICDs must have an energy source, e.g., a battery. An example of a prior battery is shown with reference to
FIG. 1 . The exploded perspective view of a prior battery solution is shown having abattery cover 10 and aheadspace insulator 12 along with abattery case 14 and an electrode assembly 16.Battery cover 10 includes afeedthrough 18 through whichfeedthrough pin 20 is inserted. Thefeedthrough pin 20 is conductively insulated from thecover 10 by glass where it passes through thecover 10. - The
feedthrough pin 20 is generally bent to align itself withconnector tabs 22 extending from electrode assembly 16. Thebattery cover 10 also includes afill port 24 used to introduce an appropriate electrolyte solution after which thefill port 24 is hermetically sealed by any suitable method. - The
headspace insulator 12 is generally located belowbattery cover 10 and above a coil insulator in the headspace above the coiled electrode assembly 16 and below thecover 10. Theheadspace insulator 12 is provided to electrically insulate thefeedthrough pin 20 fromcase 14 andbattery cover 10. Theheadspace insulator 12 forms a chamber in connection with the upper surface of the coil insulator isolating thefeedthrough pin 20 and theconnector tabs 22 to which it is attached. - While these prior battery solutions operate well to provide an energy source for an IMD there is room for improvement in the headspace design. Specifically, these prior solutions cannot hold the feedthrough pin in a uniform isolated location. In prior battery designs, a bend or a coil is formed in the feedthrough pin to act as a strain relief. This prevents the feedthrough pin from being in a rigid condition, such as if the pin was connected directly to a tab without a bend in the feedthrough pin. However, with a bend in the feedthrough pin there is little give to prevent any fatigue of the wire or the joint where the feedthrough pin enters the feedthrough through the glass during a shock or vibration event. Therefore, the bend acts as a cushion.
- The prior headspace insulator is typically a thermoformed thin-walled plastic component. It is not precisely located with respect to other internal battery components and is susceptible to deformation during the assembly process. While this condition does not present any compromise to the intent of the headspace insulator design, it can affect manufacturing yields.
- One of the variables associated with prior coiled electrode battery designs and assembly methods involves the length of the feedthrough pin between the pin-to-glass interface of the feedthrough and the pin-to-tab weld. This length is determined during the pin-to tab welding operation. Previous coiled electrode battery designs employed a “hinged” cover. The design welded the feedthrough pin to the tab(s) of one electrode of the coiled electrode assembly. The electrode assembly was then seated into the case. The cover was then seated into the case to complete the assembly. The feedthrough pin was shaped to have a coil or bend placed in the pin prior to welding the pin to the tab(s). The coil or bend in the pin was located between the glass of the feedthrough and the pin to tab weld. This coil offered strain relief to the pin, the pin-to-tab weld, and the pin-to-glass interface during electrode insertion into the case and subsequent cover insertion into the case. Due to the variations in the shape of the feedthrough pin, caused from material springiness, general handling of the pin, and the tab weld personnel, the length of the pin between the pin-to-glass interface and the pin-to-tab weld varied from one assembly to the next. This non-uniform pin length caused the case to cover insertion processing to be inconsistent.
- Attempts were made to prevent the stresses on the weld by providing a coil in the feedthrough pin. However, this increased the length of the feedthrough pin, which in turn increased the resistance of the pin. This was an undesirable result as the resistance consumed power from the battery.
- A battery in embodiments of the invention may include one or more of the following features: (a) an electrode assembly having a second electrode tab and a first electrode tab, (b) a battery case having the electrode assembly within the battery case, (c) a battery cover having a feedthrough, the battery cover being coupled to the battery case, (d) a headspace insulator having a receiving area, (e) a feedthrough assembly having a ferrule, feedthrough pin, and insulating member, the feedthrough pin having a distal end locked into the receiving area and coupled to the second electrode tab, (f) a weld bracket coupled to the battery cover, the weld bracket being coupled to the first electrode tab, (g) a second electrode opening to accept the second electrode tab, and a first electrode opening to accept the first electrode tab, (h) a case liner, (i) a coil insulator having slits, the coil insulator and the case liner enclosing the electrode assembly with the second electrode tab and the first electrode tab extending through the slits.
- A headspace insulator for a battery in an IMD in one or more embodiments of the present invention may include one or more of the following features: (a) a body of electrically and thermally insulating material disposed between a battery electrode assembly and a battery cover, (b) a receiving area within the body that receives and isolates a battery feedthrough pin, (c) an indentation within the receiving area that holds the feedthrough pin in place once the feedthrough pin is within the receiving area, (d) a raised portion that couples to a battery cover and provides an air gap between the cover and the headspace insulator near a battery case to battery cover weld areas, (e) a feedthrough aperture that receives a battery feedthrough assembly, (f) a pin aperture that receives the feedthrough pin, (g) a fillport aperture that allows an electrolyte to pass through the headspace insulator into the electrode assembly, and (h) a slot that locates a battery weld bracket and isolates it from the feedthrough pin.
- Methods of manufacturing a battery for an IMD according to the present invention may include one or more of the following steps: (a) placing a case liner and a coil insulator over an electrode assembly, (b) coupling a weld bracket to a battery cover, (c) coupling a headspace insulator to the battery cover, (d) bending the feedthrough pin, (e) locking a distal end of the feedthrough pin into a receiving area in the headspace insulator, (f) aligning the headspace insulator with the electrode assembly so a second electrode tab on the electrode assembly is accepted within a second electrode opening in the headspace insulator and a first electrode tab on the electrode assembly is accepted within a first electrode opening in the headspace insulator, (g) coupling the second electrode tab and the distal end of the feedthrough pin, (h) coupling the first electrode tab and the weld bracket, (i) placing the electrode assembly within the battery case, (j) coupling the battery cover to the battery case, (k) filling the battery case with an electrolyte through a fill port, and (l) sealing the battery with a closing ball and button.
-
FIG. 1 is an exploded perspective view of a prior battery design. -
FIG. 2 is a cutaway perspective view of a battery case, electrode assembly, case liner, coil insulator, battery cover, and a headspace insulator in an embodiment according to the present invention. -
FIG. 3 is a cutaway perspective view of the electrode assembly as shown inFIG. 2 . -
FIG. 4 is an exploded perspective view of a battery case, electrode assembly, case liner, coil insulator, battery cover, and a headspace insulator in an embodiment according to the present invention. -
FIG. 5 is a cutaway side profile view of a headspace insulator in the embodiment shown inFIG. 6 . -
FIG. 6 is an underside profile view of a headspace insulator in an embodiment of the present invention. -
FIG. 7 is an overhead profile view of a headspace insulator in an embodiment of the present invention. -
FIG. 8 is a cutaway side profile view of a headspace insulator in the embodiment shown inFIG. 6 . - The following discussion is presented to enable a person skilled in the art to make and use the invention. Various modifications to the illustrated embodiments will be readily apparent to those skilled in the art, and the generic principles herein may be applied to other embodiments and applications without departing from the spirit and scope of the present invention as defined by the appended claims. Thus, the present invention is not intended to be limited to the embodiments shown, but is to be accorded the widest scope consistent with the principles and features disclosed herein. The following detailed description is to be read with reference to the figures, in which like elements in different figures have like reference numerals. The figures, which are not necessarily to scale, depict selected embodiments and are not intended to limit the scope of the invention. Skilled artisans will recognize the examples provided herein have many useful alternatives fall within the scope of the invention.
- The present invention is not limited to ICDs and may be employed in many various types of electronic and mechanical devices for treating patient medical conditions such as pacemakers, defibrillators, neurostimulators, and therapeutic substance delivery pumps. It is to be further understood; moreover, the present invention is not limited to high current batteries and may be utilized for low or medium current batteries and for rechargeable batteries as well. For purposes of illustration only, however, the present invention is below described in the context of high current batteries.
- As used herein, the terms battery or batteries include a single electrochemical cell or cells. Batteries are volumetrically constrained systems in which the components in the case of the battery cannot exceed the available volume of the battery case. Furthermore, the relative amounts of some of the components can be important to provide the desired amount of energy at the desired discharge rates. A discussion of the various considerations in designing the electrodes and the desired volume of electrolyte needed to accompany them in, for example, a lithium/silver vanadium oxide (Li/SVO) battery is discussed in U.S. Pat. No. 5,458,997 (Crespi et al.). Generally, however, the battery must include the electrodes and additional volume for the electrolyte required to provide a functioning battery.
- With reference to
FIG. 2 , an exploded perspective view of a battery case, electrode assembly, case liner, coil insulator, battery cover, and a headspace insulator in an embodiment according to the present invention is shown. Abattery 40 according to the present invention includes acase 42 and anelectrode assembly 44.Case 42 is generally made of a medical grade titanium, however, it is contemplated thatcase 42 could be made of almost any type of metal such as aluminum and stainless steel, as long as the metal is compatible with the battery's chemistry in order to prevent corrosion. Further, it is contemplatedcase 42 could be manufactured from most any process including but not limited to machining, casting, drawing, or metal injection molding.Case 42 is designed to encloseelectrode assembly 44 and be sealed by abattery cover 46. Whilesides 48 ofcase 42 are generally planar it is contemplatedsides 48 could be generally arcuate in shape. This construction would provide a number of advantages including the ability to accommodate one of the curved or arcuate ends of a coiledelectrode assembly 44. Arcuate sides could also nest within an arcuate edge of an IMD such as an implantable cardiac defibrillator. - The details regarding construction of
electrode assembly 44, such as positive and negative electrodes, electrode pouches, etc., are secondary to the present invention and will be described generally below with a more complete discussion being found in, e.g., U.S. Pat. No. 5,458,997 (Crespi et al.). -
Electrode assembly 44 is generally a wound or coiled structure similar to those disclosed in, e.g., U.S. Pat. No. 5,486,215 (Kelm et al.). However, other electrode assembly configurations such as a folded and interleaved electrodes disclosed in, e.g., U.S. Pat No. 5,154,989 (Howard et al.) or simply individual electrodes. As a result, the electrode assemblies typically exhibit two generally planar sides, bounded by two opposing generally arcuate edges and two opposing generally planar ends. The composition of the electrode assemblies can vary, although one illustrated electrode assembly includes a wound core of lithium/silver vanadium oxide (Li/SVO) battery as discussed in, e.g., U.S. Pat. No. 5,458,997 (Crespi et al.). Other battery chemistries are also anticipated, such as those described in U.S. Pat. No. 5,180,642 (Weiss et al) and U.S. Pat. No. 4,302,518 and 4,357,215 (Goodenough et al). - With reference to
FIG. 3 , a cutaway perspective view of the electrode assembly as shown inFIG. 2 is shown.Electrode assembly 44 generally includes asecond electrode 80, afirst electrode 82, and a porous, electricallynon-conductive separator material 84 encapsulating either or both ofsecond electrode 80 andfirst electrode 82. These three components are generally placed together and wound to formelectrode assembly 44.Second electrode 80 ofelectrode assembly 44 can comprise a number of different materials including second electrode active material located on a second electrode conductor element. In this embodiment the second electrode is an anode in the case of a primary cell or the negative electrode in the case of a rechargeable cell. Examples of suitable electrode active materials include, but are not limited to: alkali metals, materials selected from Group IA of the Periodic Table of Elements, including lithium, sodium, potassium, etc., and their alloys and intermetallic compounds including, e.g., Li—Si, Li—B, and Li—Si—B alloys and intermetallic compounds, insertion or intercalation materials such as carbon, or tin-oxide. Examples of suitable materials for anode or negative electrode conductor element include, but are not limited to: stainless steel, nickel, or titanium. The details regarding construction ofelectrode assembly 44, such as positive and negative electrodes, are described with a more complete discussion being found in, e.g., U.S. Pat. No. 5,439,760 (Howard et al.). -
First electrode portion 82 ofelectrode assembly 44 generally includes a first electrode active material located on a first electrode current collector, which also conducts the flow of electrons between the first electrode active materials, and first electrode terminals ofelectrode assembly 44. In this embodiment the first electrode is a cathode in the case of a primary cell or the positive electrode in the case of a rechargeable cell. Examples of materials suitable for use as first electrode active material include, but are not limited to: a metal oxide, a mixed metal oxide, a metal, and combinations thereof. Suitable first electrode active materials include silver vanadium oxide (SVO), copper vanadium oxide, copper silver vanadium oxide (CSVO), manganese dioxide, titanium disulfide, copper oxide, copper sulfide, iron sulfide, iron disulfide, and fluorinated carbon, and mixtures thereof, including lithiated oxides of metals such as manganese, cobalt, and nickel. - Generally, cathode or positive electrode active material comprises a mixed metal oxide formed by chemical addition, reaction or otherwise intimate contact or by thermal spray coating process of various metal sulfides, metal oxides or metal oxide/elemental metal combinations. The materials thereby produced contain metals and oxides of Groups IB, IIB, IIIB, IVB, VB, VIB, VIIB, and VIII of the Periodic Table of Elements, which includes noble metals and/or their oxide compounds.
- First cathode and positive electrode materials can be provided in a binder material such as a fluoro-resin powder, generally polyvinylidine fluoride or polytetrafluoroethylene (PTFE) powder also includes another electrically conductive material such as graphite powder, acetylene black powder, and carbon black powder. In some cases, however, no binder or other conductive material is required for the first electrode.
-
Separator material 84 should electrically insulatesecond electrode 80 fromfirst electrode 82. The material is generally wettable by the cell electrolyte, sufficiently porous to allow the electrolyte to flow throughseparator material 84, and maintain physical and chemical integrity within the cell during operation. Examples of suitable separator materials include, but are not limited to: polyethylenetetrafluoroethylene, ceramics, non-woven glass, glass fiber material, polypropylene, and polyethylene. As illustrated,separator 84 consists of three layers. A polyethylene layer is sandwiched between two layers of polypropylene. The polyethylene layer has a lower melting point than the polypropylene and provides a shut down mechanism in case of cell over heating. The electrode separation is different than other lithium-ion cells in that two layers of separator are used betweensecond electrode 80 andfirst electrode 82. - As illustrated, the electrolyte solution can be an alkali metal salt in an organic solvent such as a lithium salt (i.e. 1.0M LiCIO4 or LiAsF6) in a 50/50 mixture of propylene carbonate and dimethoxyethane.
- As best seen in
FIG. 4 , acoil insulator 54 is located onelectrode assembly 44 when assembled, which is discussed in more detail below.Coil insulator 54 includesslits first electrode tab 52 andsecond electrode tab 50.Coil insulator 54 further includesaperture 61 allowing electrolyte to enter and surroundelectrode assembly 44. Generallyinsulator 54 is comprised of ETFE, however, it is contemplated other materials could be used such as HDDE, polypropylene, polyurethane, fluoropolymers, and the like.Insulator 54 performs several functions including working in conjunction withcase liner 60 to isolatecase 42 and cover 46 fromelectrode assembly 44. It also provides mechanical stability forelectrode assembly 44. In addition, it serves to holdelectrode assembly 44 together which substantially aids in the manufacturing ofbattery 40. -
Electrode assembly 44 is also generally inserted into an electricallynon-conductive case liner 60 during assembly.Case liner 60 generally extends at its top edge above the edge ofelectrode assembly 44 to overlap withcoil insulator 54.Case liner 60 is generally comprised of ETFE, however, other types of materials are contemplated such as polypropylene, silicone rubber, polyurethane, fluoropolymers, and the like.Case liner 60 generally has substantially similar dimensions tocase 42 exceptcase liner 60 would have slightly smaller dimensions so it can rest inside ofbattery case 42. -
FIGS. 2 and 4 also depictbattery cover 46 and aheadspace insulator 62 along withcase 42 andelectrode assembly 44. Similar tocase 42, cover 46 is comprised of medical grade titanium to provide a strong and reliable weld creating a hermetic seal withbattery case 42. However, it is contemplatedcover 46 could be made of any type of material as long as the material was electrochemically compatible.Illustrated battery cover 46 includes afeedthrough aperture 64 through whichfeedthrough assembly 68 is inserted. Feedthrough assembly contains aferrule 67, a insulatingmember 65, and afeedthrough pin 66.Feedthrough pin 66 is comprised of niobium; however, any conductive material could be utilized without departing from the spirit of the invention. Niobium is generally chosen for its low resistivity, its material compatibility during welding with titanium, and its coefficient of expansion when heated. Niobium and titanium are compatible metals, meaning when they are welded together a strong reliable weld is created. -
Feedthrough pin 66 is generally conductively insulated fromcover 46 byfeedthrough assembly 68 where it passes throughcover 46. Insulatingmember 65 is comprised of CABAL-12 (calcium-boro-aluminate), TA-23 glass or other glasses, which provides electrical isolation offeedthrough pin 66 fromcover 46. The pin material is in part selected for its ability to join with insulatingmember 65, which results in a hermetic seal. CABAL-12 is very corrosion resistant as well as a good insulator. Therefore, CABAL-12 provides for good insulation betweenpin 66 and cover 46 as well as being resistant to the corrosive effects of the electrolyte. However, other materials besides glass can be utilized, such as ceramic materials, without departing from the spirit of the invention.Battery cover 46 also includes afill port 70 used to introduce an appropriate electrolyte solution after which fillport 70 is hermetically sealed by any suitable method. -
Headspace insulator 62 is generally located belowbattery cover 46 and abovecoil insulator 54, i.e., in the headspace above coiledelectrode assembly 44 and below thecover 46. Generally,headspace insulator 62 is comprised of ETFE (Ethylene Tetrafluoroethylene), however, other insulative materials are contemplated such as polypropylene. ETFE is stable at bothsecond electrode 80 andfirst electrode 82 potentials and has a relatively high melting temperature.Headspace insulator 62 preferably coversdistal end 72 offeedthrough pin 66,first electrode tab 52, andsecond electrode tab 50. Whileelectrode assembly 44 is described as having a first and second electrode tab, it is fully contemplated each electrode could have a plurality of tabs without departing from the spirit of the invention.Insulator 62 is designed to provide thermal protection to coiledelectrode assembly 44 from theweld joining case 42 and cover 46 by providing an air gap between the headspace insulator and the cover in the area of the case to cover weld.Insulator 62 prevents electrical shorts by providing electrical insulation between thefirst electrode tab 52,second electrode tab 50, andbracket 74 and their conductive surfaces. Illustratedweld bracket 74 serves as conductor betweenfirst electrode tab 52 andbattery cover 46.Weld bracket 74 is a nickel foil piece that is welded to bothcover 46 andfirst electrode tab 52. -
Battery 40 inFIGS. 2 and 4 can be thought of as consisting of three major functional portions. They are the encasement, insulation, and active component portions. The encasement or closure portion consists ofcase 42,cover 46,feedthrough assembly 68,fillport 70,ball 112,button 114, and electrical connections. The major functions of the encasement are to provide a hermetic seal, a port for adding electrolyte and isolated electrical connections. The major function of the insulators is to prevent electrical shorts. The insulators consist ofheadspace insulator 62,coil insulator 54, andcase liner 60. The active portion of the cell is where the electrochemistry/energy storage occurs. It consists of the electrolyte andcoiled electrode assembly 44.Coiled electrode assembly 44 consists ofsecond electrode 80,first electrode 82, and two layers ofseparator 84. - With reference to
FIG. 5 , a cutaway side profile view of a headspace insulator in the embodiment shown inFIG. 6 is shown. As illustrated,headspace insulator 62 has a generally parallelepiped shape and has a solid construction except for portions ofinsulator 62 which are missing and will be discussed below. A raisedportion 90 contacts the underside ofbattery cover 46 and provides an air gap betweencover 46 andinsulator 62 near the weld areas wherecover 46 andcase 42 meet (seeFIG. 7 and 8). Generally, raisedportion 90 is positioned to the underside ofbattery cover 46. It is contemplatedinsulator 62 could be attached to the underside ofbattery cover 46 in other fashions, such as, a snapping assembly, or fasteners without departing from the spirit of the present invention.Feedthrough aperture 92 receives feedthrough assembly 68 (shown inFIG. 4 ) when insulator 62 (shown inFIG. 4 ) is placed on battery cover 46 (shown inFIG. 4 ) as will be discussed in detail below. Similarly,pin aperture 94 receives feedthrough pin 66 (shown inFIG. 4 ). As can be seen, an inner portion ofpin aperture 94 has acurvature 96, which provides support forpin 66 when the manufacturer bends pin 66 (shown inFIG. 4 ) after insertion to placedistal end 72 into receivingarea 98. Receiving area acts to holddistal end 72 still during any shock or vibration occurrences as well as isolate pin 66 (shown inFIG. 4 ) from contact with any other polarized surfaces.Indentations 100 assist to hold distal end 72 (shown inFIG. 4 ) in place oncedistal end 72 is pressed into receivingarea 98, as will be described in more detail below. As can be further seen, there is a second electrode opening 102 for receivingsecond electrode tab 50 and afirst electrode opening 104 for receivingfirst electrode tab 52. There is also afillport aperture 106, which allows electrolyte to pass throughinsulator 62 toelectrode assembly 44. - With reference to
FIG. 6 , an underside profile view of a headspace insulator in an embodiment of the present invention is shown. As can be shown,insulator 62 has aslot 108 to receiveweld bracket 74.Slot 108 allows forweld bracket 74 to fit betweeninsulator 62 and the inside surface ofbattery case 42.Slot 108 is also isolated from receivingarea 98 and second electrode opening 102 to prevent any shorting between the positive and negative polarities. Further shown inFIG. 6 ispin aperture 94, receivingarea 98,indentations 100,second electrode opening 102,first electrode opening 104, andfillport aperture 106. - With reference to
FIG. 7 , an overhead profile view of a headspace insulator in an embodiment of the present invention is shown. Further shown is feedthroughaperture 92,pin aperture 94, raisedportion 90,slot 108, andfillport aperture 106. - With reference again to
FIGS. 2 and 4 ,battery 40 is generally constructed according to the discussion below.Battery 40 can be put together in three sections. Section one containsbattery case 42. Section two containscase liner 60,electrode assembly 44, andcoil insulator 54. Section three containsheadspace insulator 62,battery cover 46,weld bracket 74,feedthrough pin 66, andfeedthrough assembly 68. With section two,case liner 60 andcoil insulator 54 are placed overelectrode assembly 44 withsecond electrode tab 50 andfirst electrode tab 52 extending throughslits weld bracket 74 is welded to cover 46. Raisedportion 90 ofheadspace insulator 62 is positioned on the underside ofcover 62 withslot 108 acceptingweld bracket 74.Feedthrough assembly 68 withfeedthrough pin 66 is inserted intofeedthrough 64 and accepted byfeedthrough aperture 92 andpin aperture 94 respectively.Feedthrough pin 66 is then bent over alongcurvature 96 towards receivingarea 98.Feedthrough pin 66 is then placed into receivingarea 98 and locked into place byindentations 100. This electrically isolatesfeedthrough pin 66 fromcase 42,cover 46,weld bracket 74,first electrode tab 52 or any other element which has an opposing polarity tofeedthrough pin 66. - The section three assembly is then aligned with the section two assembly so
second electrode tab 50 is accepted withinsecond electrode opening 102 andfirst electrode tab 52 is accepted withinfirst electrode opening 104 wheresecond electrode tab 50 is adjacent todistal end 72 offeedthrough pin 66 andfirst electrode tab 52 is adjacent toweld bracket 74.Second electrode tab 50 anddistal end 72 offeedthrough pin 66 are then welded together as isfirst electrode tab 52 andweld bracket 74. It is contemplated other methods of attachment could be used such as rivets and crimping without departing from the spirit of the invention. At this point the assembly can be inserted it intobattery case 42.Cover 46 is then laser welded tobattery case 42.Battery 40 is then filled full of electrolyte throughfill port 70 and sealed with aclosing ball 112 andbutton 114 and welded shut to hermetically sealbattery 40. It is contemplated the steps for manufacturingbattery 40 can be alternated without departing from the spirit of the invention. -
Insulator 62 provides many advantages over the prior solutions.Insulator 62 provides an insulating layer aroundferrule 67 that preventsfeedthrough pin 66 from electrically shorting toferrule 67.Insulator 62 provides for receivingarea 98 that locatesfeedthrough pin 66 in a fixed location which is reproducible from battery to battery. Receivingarea 98 has indentations which lockfeedthrough pin 66 into receivingarea 98.Insulator 62 provides forslot 108 to provide a fixed location forweld plate 74.Insulator 62 provides raisedportion 90 which provides an air gap and keepsinsulator 62 away form the weld areas joining thecase 42 to cover 46 to prevent any melting ofinsulator 62.Insulator 62 providesopenings weld tabs bracket 74 respectively.Insulator 62 isolates the different polarities ofbattery 40, by creating a physical barrier betweentab 50/pin 66 andtab 52/bracket 74/case 42/cover 46.Insulator 62 is fixed with respect tofeedthrough pin 66 andtabs insulator 62, when assembled withelectrode assembly 44 andcoil insulator 54, forms an assembly that can be inserted intocase 42 without distorting or bendingfeedthrough pin 66 ortabs - It will be appreciated the present invention can take many forms and embodiments. The true essence and spirit of this invention are defined in the appended claims, and it is not intended the embodiment of the invention presented herein should limit the scope thereof.
Claims (4)
1. A method of manufacturing a battery for an implantable medical device, comprising:
placing a case liner and a coil insulator over an electrode assembly;
coupling a weld bracket to a battery cover;
coupling a headspace insulator to the battery cover;
bending the feedthrough pin;
locking a distal end of the feedthrough pin into a receiving area in the headspace insulator;
aligning the headspace insulator with the electrode assembly so a second electrode tab on the electrode assembly is accepted within a second electrode opening in the headspace insulator and a first electrode tab on the electrode assembly is accepted within a first electrode opening in the headspace insulator;
coupling the second electrode tab and the distal end of the feedthrough pin;
coupling the first electrode tab and the weld bracket;
placing the electrode assembly within the battery case; and
coupling the battery cover to the battery case.
2. A method according to claim 1 , further comprising the step of filling the battery case with an electrolyte through a fill port.
3. A method according to claim 2 , further comprising the step of sealing the battery case with a closing ball and button.
4. A method according to claim 1 , wherein the coil insulator is comprised of slits to receive the first electrode tab and the second electrode tab.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
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US11/861,344 US20080010816A1 (en) | 2003-11-26 | 2007-09-26 | Headspace insulator for electrochemical cells |
Applications Claiming Priority (2)
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US10/723,317 US7294432B2 (en) | 2003-11-26 | 2003-11-26 | Battery having improved headspace insulator |
US11/861,344 US20080010816A1 (en) | 2003-11-26 | 2007-09-26 | Headspace insulator for electrochemical cells |
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US10/723,317 Division US7294432B2 (en) | 2003-11-26 | 2003-11-26 | Battery having improved headspace insulator |
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US20080010816A1 true US20080010816A1 (en) | 2008-01-17 |
Family
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US10/723,317 Active 2025-04-16 US7294432B2 (en) | 2003-11-26 | 2003-11-26 | Battery having improved headspace insulator |
US11/861,344 Abandoned US20080010816A1 (en) | 2003-11-26 | 2007-09-26 | Headspace insulator for electrochemical cells |
US11/861,341 Active 2026-02-01 US7927738B2 (en) | 2003-11-26 | 2007-09-26 | Battery having improved headspace insulator |
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US10/723,317 Active 2025-04-16 US7294432B2 (en) | 2003-11-26 | 2003-11-26 | Battery having improved headspace insulator |
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US11/861,341 Active 2026-02-01 US7927738B2 (en) | 2003-11-26 | 2007-09-26 | Battery having improved headspace insulator |
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Cited By (1)
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CN104953061A (en) * | 2015-05-29 | 2015-09-30 | 浙江西凯新能源开发有限公司 | Battery shell, making method thereof, and battery with battery shell |
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US7408762B2 (en) * | 2004-07-16 | 2008-08-05 | Cardiac Pacemakers, Inc. | Method and apparatus for providing capacitor feedthrough |
US7420797B2 (en) * | 2004-07-16 | 2008-09-02 | Cardiac Pacemakers, Inc. | Plug for sealing a capacitor fill port |
US7164574B2 (en) | 2004-07-16 | 2007-01-16 | Cardiac Pacemakers, Inc. | Method and apparatus for openings in a capacitor case |
US7544220B2 (en) * | 2005-03-31 | 2009-06-09 | Medtronic, Inc. | Welding methods and apparatus for batteries |
WO2007039999A1 (en) * | 2005-09-30 | 2007-04-12 | Densei-Lambda Kabushiki Kaisha | Battery pack |
US8179663B2 (en) * | 2005-10-31 | 2012-05-15 | Medtronic, Inc. | Capacitor liner |
US7733631B2 (en) * | 2005-10-31 | 2010-06-08 | Medtronic, Inc. | Capacitor liner |
US20070150020A1 (en) * | 2005-12-28 | 2007-06-28 | Hokanson Karl E | Externally oriented battery feedthrough with integral connector |
US7442466B2 (en) * | 2006-01-31 | 2008-10-28 | Medtronic, Inc. | Access port for use in electrochemical cells |
US20080000882A1 (en) * | 2006-06-01 | 2008-01-03 | Vanderlick Stephen W | Method and apparatus for a foil to control heat flow from welding a device case |
US7879488B2 (en) * | 2006-08-28 | 2011-02-01 | Cardiac Pacemakers, Inc. | Apparatus and method for a power source casing with a stepped bevelled edge |
US10449373B2 (en) | 2009-07-31 | 2019-10-22 | Medtronic, Inc. | Connector enclosure assemblies of medical devices including an angled lead passageway |
US9848423B2 (en) * | 2014-10-31 | 2017-12-19 | Realtek Semiconductor Corp. | Wireless communication system and associated wireless communication method |
US10629862B2 (en) * | 2016-11-04 | 2020-04-21 | Greatbatch Ltd. | Cathode insulator design |
US12011606B2 (en) | 2019-12-31 | 2024-06-18 | Medtronic, Inc. | Intermediate member with protrusions for medical device battery assemblies |
US20220370811A1 (en) * | 2021-05-19 | 2022-11-24 | Medtronic, Inc. | Folded headspace insulator |
CN113487916B (en) * | 2021-09-08 | 2021-11-02 | 中矽科技股份有限公司 | Aircraft traffic control collision avoidance system |
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US6040082A (en) * | 1997-07-30 | 2000-03-21 | Medtronic, Inc. | Volumetrically efficient battery for implantable medical devices |
US6224999B1 (en) * | 1999-07-23 | 2001-05-01 | Wilson Greatbatch Ltd. | Header insulator with bosses |
US20040023109A1 (en) * | 2000-04-19 | 2004-02-05 | Robert Rusin | One-piece lid supporting an insert-molded feedthrough assembly for an electrical energy storage device |
-
2003
- 2003-11-26 US US10/723,317 patent/US7294432B2/en active Active
-
2007
- 2007-09-26 US US11/861,344 patent/US20080010816A1/en not_active Abandoned
- 2007-09-26 US US11/861,341 patent/US7927738B2/en active Active
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US6040082A (en) * | 1997-07-30 | 2000-03-21 | Medtronic, Inc. | Volumetrically efficient battery for implantable medical devices |
US6224999B1 (en) * | 1999-07-23 | 2001-05-01 | Wilson Greatbatch Ltd. | Header insulator with bosses |
US20040023109A1 (en) * | 2000-04-19 | 2004-02-05 | Robert Rusin | One-piece lid supporting an insert-molded feedthrough assembly for an electrical energy storage device |
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CN104953061A (en) * | 2015-05-29 | 2015-09-30 | 浙江西凯新能源开发有限公司 | Battery shell, making method thereof, and battery with battery shell |
Also Published As
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US7927738B2 (en) | 2011-04-19 |
US7294432B2 (en) | 2007-11-13 |
US20050112460A1 (en) | 2005-05-26 |
US20080008931A1 (en) | 2008-01-10 |
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