US20230078781A1 - Polymer dipped pouch cell - Google Patents
Polymer dipped pouch cell Download PDFInfo
- Publication number
- US20230078781A1 US20230078781A1 US18/049,079 US202218049079A US2023078781A1 US 20230078781 A1 US20230078781 A1 US 20230078781A1 US 202218049079 A US202218049079 A US 202218049079A US 2023078781 A1 US2023078781 A1 US 2023078781A1
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- US
- United States
- Prior art keywords
- pouch
- lithium
- copper foil
- active material
- cell
- 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.)
- Pending
Links
- 229920000642 polymer Polymers 0.000 title description 4
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims abstract description 75
- 239000011149 active material Substances 0.000 claims abstract description 35
- 239000011889 copper foil Substances 0.000 claims abstract description 33
- WHXSMMKQMYFTQS-UHFFFAOYSA-N Lithium Chemical compound [Li] WHXSMMKQMYFTQS-UHFFFAOYSA-N 0.000 claims abstract description 28
- 229910052744 lithium Inorganic materials 0.000 claims abstract description 28
- 239000003792 electrolyte Substances 0.000 claims abstract description 10
- 238000000034 method Methods 0.000 claims description 29
- 239000011888 foil Substances 0.000 claims description 13
- 229910044991 metal oxide Inorganic materials 0.000 claims description 10
- 150000004706 metal oxides Chemical class 0.000 claims description 10
- 229920002367 Polyisobutene Polymers 0.000 claims description 9
- -1 polypropylene Polymers 0.000 claims description 5
- 238000007789 sealing Methods 0.000 claims description 4
- 239000004743 Polypropylene Substances 0.000 claims description 3
- 229920001155 polypropylene Polymers 0.000 claims description 3
- 229910052802 copper Inorganic materials 0.000 abstract description 6
- 239000010949 copper Substances 0.000 abstract description 6
- 210000004027 cell Anatomy 0.000 description 37
- 239000011248 coating agent Substances 0.000 description 14
- 238000000576 coating method Methods 0.000 description 14
- 239000000853 adhesive Substances 0.000 description 12
- 230000001070 adhesive effect Effects 0.000 description 12
- 238000010276 construction Methods 0.000 description 9
- 239000000463 material Substances 0.000 description 4
- 230000008901 benefit Effects 0.000 description 3
- 238000010586 diagram Methods 0.000 description 3
- VLKZOEOYAKHREP-UHFFFAOYSA-N n-Hexane Chemical compound CCCCCC VLKZOEOYAKHREP-UHFFFAOYSA-N 0.000 description 3
- 239000002086 nanomaterial Substances 0.000 description 3
- 239000007787 solid Substances 0.000 description 3
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 2
- 230000002378 acidificating effect Effects 0.000 description 2
- 238000001035 drying Methods 0.000 description 2
- 238000004519 manufacturing process Methods 0.000 description 2
- 239000002904 solvent Substances 0.000 description 2
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 2
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- 239000004698 Polyethylene Substances 0.000 description 1
- 239000002390 adhesive tape Substances 0.000 description 1
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 1
- 229920005549 butyl rubber Polymers 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 239000006182 cathode active material Substances 0.000 description 1
- 210000003850 cellular structure Anatomy 0.000 description 1
- 238000010073 coating (rubber) Methods 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- 239000004020 conductor Substances 0.000 description 1
- 238000004090 dissolution Methods 0.000 description 1
- 239000000975 dye Substances 0.000 description 1
- 239000007772 electrode material Substances 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 239000010408 film Substances 0.000 description 1
- 239000003292 glue Substances 0.000 description 1
- 239000011810 insulating material Substances 0.000 description 1
- 239000012212 insulator Substances 0.000 description 1
- 238000002955 isolation Methods 0.000 description 1
- 239000011855 lithium-based material Substances 0.000 description 1
- 230000000873 masking effect Effects 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000011104 metalized film Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 229910052759 nickel Inorganic materials 0.000 description 1
- 229910052760 oxygen Inorganic materials 0.000 description 1
- 239000001301 oxygen Substances 0.000 description 1
- 239000003973 paint Substances 0.000 description 1
- 239000000049 pigment Substances 0.000 description 1
- 229920000573 polyethylene Polymers 0.000 description 1
- 239000002002 slurry Substances 0.000 description 1
- 239000007921 spray Substances 0.000 description 1
Images
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- H01M4/02—Electrodes composed of, or comprising, active material
- H01M4/36—Selection of substances as active materials, active masses, active liquids
- H01M4/38—Selection of substances as active materials, active masses, active liquids of elements or alloys
- H01M4/381—Alkaline or alkaline earth metals elements
- H01M4/382—Lithium
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- H01M10/052—Li-accumulators
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- H01M10/058—Construction or manufacture
- H01M10/0583—Construction or manufacture of accumulators with folded construction elements except wound ones, i.e. folded positive or negative electrodes or separators, e.g. with "Z"-shaped electrodes or separators
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- H01M10/0585—Construction or manufacture of accumulators having only flat construction elements, i.e. flat positive electrodes, flat negative electrodes and flat separators
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- H01M50/102—Primary casings; Jackets or wrappings characterised by their shape or physical structure
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- H01M50/174—Arrangements of electric connectors penetrating the casing adapted for the shape of the cells
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- H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
- H01M50/204—Racks, modules or packs for multiple batteries or multiple cells
- H01M50/207—Racks, modules or packs for multiple batteries or multiple cells characterised by their shape
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- H01M50/233—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by physical properties of casings or racks, e.g. dimensions
- H01M50/24—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by physical properties of casings or racks, e.g. dimensions adapted for protecting batteries from their environment, e.g. from corrosion
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- H01M50/547—Terminals characterised by the disposition of the terminals on the cells
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- H01M2004/026—Electrodes composed of, or comprising, active material characterised by the polarity
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- 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
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
- Y02E60/10—Energy storage using batteries
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- 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
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- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
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- Y02P70/50—Manufacturing or production processes characterised by the final manufactured product
Definitions
- This disclosure relates to battery technology in general and, more particularly, to improved construction methods for battery cells.
- the invention of the present disclosure in one aspect thereof, comprises a pouch cell including a copper foil forming a pouch, an active material layer adjacent to the copper foil inside the pouch forming a cathode with the copper, and a lithium-based anode inside the pouch.
- the cell also includes a separator interposing the one active material layer and the lithium-based anode, and an electrolyte.
- the active material forms an anode with the copper and the cathode is a lithium-based cathode.
- the active material comprises an acidified metal oxide.
- the active material may be applied in at least one layer inside the pouch and has a density of about 6.49 mg/cm2.
- the separator may comprise a pouch containing the lithium-based anode.
- the separator may be polypropylene.
- the pouch cell may comprises a unitary segment of copper foil folded to create the pouch.
- the segment of copper foil may have a folded edge forming a bottom of the pouch and opposite sides of the pouch adjacent to the folded bottom edge are sealed together.
- the cell may include a first terminal tab electrically connected to the lithium-based anode and accessible outside the pouch.
- a second terminal tab may be electrically connected to the copper foil pouch.
- the lithium-based anode may be a lithium foil. In some cases, the lithium-based anode consists of metallic lithium.
- the pouch cell may have an insulating layer applied to an outside of the copper foil pouch.
- the insulating layer may comprise polyisobutylene.
- the invention of the present disclosure in another aspect thereof, comprises a method of forming a battery cell.
- the method includes preparing a copper foil pouch, lining an interior portion of the copper foil pouch with an active material to create a cathode pouch, providing a lithium-based foil anode surrounded by a separator inside the pouch. An electrolyte is be provided inside the pouch. The pouch is sealing upon completion.
- the method includes attaching a first electrical tab as a terminal to the cathode inside the pouch and routing the electrical tab to outside the pouch.
- the method may include affixing a second electrical tab to the copper foil pouch. Coating an outside of the copper foil pouch with an insulating material may also form part of the method.
- the invention of the present disclosure in another aspect thereof, comprises a battery cell having a copper foil pouch having an opening end and a folded end and opposite sealed-together sides.
- the cell includes an active material lining the copper foil pouch, a segment of lithium foil inside a separator inside the pouch, and a first terminal affixed to the lithium foil and accessibly outside the pouch.
- the copper foil pouch contains an electrolyte and is sealed at the opening end and encloses the lithium foil, separator, and electrolyte inside the pouch, and provides a working voltage between the copper pouch and the first terminal.
- the copper foil has a second terminal affixed thereto and provides the working voltage between the first and second terminals.
- Some embodiments include an electrically insulating polymer coating applied to an outside of the copper foil pouch.
- FIG. 1 is an outside view of a pouch cell according to aspects of the present disclosure.
- FIG. 2 is an exploded perspective view of the pouch cell of FIG. 1 .
- FIG. 3 is a top down view of a pouch cell under construction according to aspects of the present disclosure.
- FIG. 4 is a top down view of a the pouch cell of FIG. 2 after further construction according to aspects of the present disclosure.
- FIG. 5 is a flow chart of a pouch cell production process according to aspects of the present disclosure.
- the present disclosure describes construction of pouch-type cells based upon various battery chemistries.
- the present disclosure is not intended to be specific to any chemistry (unless so claimed).
- the methods and constructions used herein are known to function well with acidified metal oxides as active electrode materials such as those described in U.S. Pat. No. 9,786,910 to Johnson, et al. (herein incorporated by reference), and related materials.
- the pouch cell comprises an outer pouch 102 , which may comprise a metallic foil such as a copper foil.
- the copper foil may be replaced with a polymer metalized film.
- Such film may also be coated with an outer insulative layer as described below.
- a mesh current collector (not shown) may also be used, along with sufficient outer insulative coating(s).
- the outer pouch 102 may be fully or partially coated of covered with an insulating coating 108 .
- the coating 108 may be configured to conform to the shape of the pouch 102 and may be sufficiently malleable not to flake or crack from movement of deflection of the pouch 102 .
- a butyl rubber coating is applied such as polyisobutylene (PIB).
- PIB polyisobutylene
- a 2% PIB/Hexane solution may be prepared, and the pouch 102 dipped into the same resulting in a PIB outer coating 108 that prevents shorting and electrically isolates components such as terminals 104 , 106 from the copper foil.
- the PIB coating 108 thus forms a case for the pouch cell 100 that conforms to the shape of the pouch 102 .
- the coating 108 on the copper foil pouch 102 may be transparent or may be colored by various dyes, pigments, paints, or the like. Insulators other than PIB may also be used for the coating 108 . Polymers dispersed in solvents may form the basis of an insulative coating 108 for the copper foil pouch 102 . In some embodiments, the coating 108 is sprayed or painted on, and possibly actively or passively cured.
- the pouch 100 is provided with an externally accessible cathode terminal 104 and an externally accessible anode terminal 106 . These may also be denoted a positive terminal 104 and a negative terminal 106 .
- the terminals 104 , 106 may comprise nickel or another suitable conductor that does not react negatively with the other cell components.
- the terminals 104 , 106 are ultrasonically welded in place in some embodiments. As illustrated, the terminals 104 , 106 are metallic tabs to which clips or other fasteners may be selectively connected. However, it should be understood that the terminals 104 , 106 may take whatever shape and form is necessary as is known in the art and useful for attaching the cell 100 as a subcomponent of a completed battery, or to a specific load.
- the pouch 102 comprises a layer of copper foil having a fold 202 near the middle thereof.
- the fold 202 in the copper foil creates two halves of the pouch 102 with opposite sides 204 , 206 .
- Opposite the fold 202 is a pouch mouth end 208 .
- On the inner side of the copper foil of the pouch 102 is an active material layer 210 .
- the active material layer 210 may be on both inner sides of the pouch 102 and, in contact with the copper foil form a cathode.
- the active material 210 may be deposited as a slurry that is then cured or dried.
- the active material 210 may be spray applied. In some embodiments, layers of material are applied, possibly with carbon layers between.
- an active material is one that, when placed in contact with the copper foil of the pouch 102 , a cathodic structure will result that may be used with an electrolyte, separator, and anode to function as a battery cell. In other embodiments, the active material 210 forms an anode with the copper and the cathode is a lithium-based cathode.
- the active material 210 is a surface-functionalized, acidified metal oxide, as described in U.S. Pat. No. 9,786,910.
- the active material 210 may comprise, for example, at least one solid metal oxide nanomaterial including a surface that is acidic but not superacidic, the surface having a pH ⁇ 5 when re-suspended, after drying, in water at 5 wt % and a Hammett function H 0 > ⁇ 12.
- the active material 210 may be said to comprise a solid metal oxide nanomaterial being in a form M m O x /G, where M m is a metal, O x is total oxygen, M m O x is a metal oxide, G is at least one electron-withdrawing surface group, and “/” makes a distinction between the metal oxide and the electron-withdrawing surface group, the battery electrode solid metal oxide nanomaterial having a pH ⁇ 5 when re-suspended, after drying, in water at 5 wt % and a Hammett function H 0 > ⁇ 12, at least on its surface.
- cells may be constructed based on the present disclosure that do not utilize acidic metal oxides as active materials.
- the size, volume, or area of the cathode active material 210 may vary, but overall size corresponds to overall capacity of the cell 100 . Additionally, in various illustrated embodiments, the total size of the cathode is reflected in the folding or doubling over during assembly of the completed cell.
- the thickness of active material may vary. In one embodiment, the active material is applied at a density of 6.49 mg/cm 2 .
- the ends and sides of the copper foil pouch 102 may be left free of active material to allow the foil to be folded and sealed (e.g., the folded end 202 , the mouth end 208 , and or the opposite sides 204 , 206 may not have active material 210 applied thereon.
- a single-piece or multi-piece adhesive strip 212 may bind the edges of the two halves of the pouch 102 together.
- the adhesive strip 212 may be tape, glue, or anther adhesive.
- the adhesive strip 212 may be chosen such that the pouch 102 will seal to contain electrolytes and other internal battery components without dissolution of the adhesive strip 212 .
- the copper foil of the pouch 102 may be cut at the fold 202 to allow easier application of the adhesive strip 212 .
- a separator 214 interposing the active material 210 and an anode 216 .
- the separator 214 may be suitable to the internal chemistry of the cell 100 .
- the separator 214 comprises Targray polypropylene or polyethylene.
- the separator 214 may be a folded material or formed into a pouch such that is completely enclosed the anode 216 and insulates it from electrical contact with the active material 210 acting as a cathode.
- a segment of adhesive tape (not shown) or other device may secure the separator 214 in place around the anode 216 during pouch/cell assembly. The tape or other insulating adhesive may also serve to prevent contact between the anode tab 106 and the copper foil 102 during assembly.
- the anode 216 may be a lithium-based material. If active materials 210 are used corresponding to those described in U.S. Pat. No. 9,786,910, a pure lithium foil may safely be used as the anode 216 . In other embodiments, other known lithium-based compounds may be used. In some embodiments, the anode 216 comprises lithium foil having a thickness of about 1 mm.
- a compatible electrolyte 220 may complete the cell 100 and may be inserted into the pouch 102 prior to final sealing of the pouch 102 .
- FIG. 3 a top down view of the pouch cell 100 as it would appear under construction according to aspects of the present disclosure is shown.
- the pouch 102 is unfolded (or not yet folded) on fold 202 with opposite sides 204 , 206 shown.
- Active material 210 has been applied to the inner surface of the pouch 102 with a margin allowing for sealing of the pouch 102 . It may be necessary to remove active material from an area around the fold 202 as shown by 302 .
- FIG. 4 a top down view of a the pouch cell of FIG. 2 after further construction according to aspects of the present disclosure is shown.
- active material 110 has been removed from the area 302 around the fold 202 . This may be accomplished by application and removal of masking tape that may pull active material away from the pouch 102 . In other embodiments, a suitable solvent or other method may be used. A portion of the adhesive strip 212 may be applied along sides 204 , 206 before the pouch 102 is folded at fold 202 .
- the mouth 208 of the pouch 102 is folded together and sealed. This may be with or without a portion of the adhesive strip 212 or another adhesive to seal the fold.
- FIG. 5 is a flow chart 500 of a pouch cell production process according to aspects of the present disclosure is shown.
- the method as illustrated by flow chart 500 is exemplary only. If different materials or construction methods are employed, the construction method may be adapted accordingly.
- the copper foil pouch 102 is prepared.
- the active material 210 is applied. This may include ensuring proper clearance at the margins to be sealed.
- the foil is folded and sealed (e.g., with adhesive) as a pouch 102 with an open end 208 .
- a tab or terminal 104 may be affixed to the foil at step 516 .
- a terminal 106 is affixed to an anode 216 .
- the anode is wrapped in a separator 214 at step 520 .
- the anode is placed in the pouch 102 .
- Electrolyte may be added at step 524 .
- the open end 208 of the pouch 102 may be sealed by folding, application of adhesive, or other methods at step 526 .
- the pouch 102 may have coating 108 applied thereto to insulate the pouch 102 .
- a pouch cell was constructed as described above.
- the completed pouch cell was tested to confirm that the PIB coating provided adequate electrical isolation and resistance to internal components of the pouch cell.
- the completed cell was also used to power loads such as LEDs.
- a pouch cell having an active material area as small as 2 cm ⁇ 2 cm per side, surrounding a 1 mm thick 1.8 cm ⁇ 1.8 cm lithium foil anode has also been shown to effectively power loads such as LEDs.
- Methods of the present invention may be implemented by performing or completing manually, automatically, or a combination thereof, selected steps or tasks.
- method may refer to manners, means, techniques and procedures for accomplishing a given task including, but not limited to, those manners, means, techniques and procedures either known to, or readily developed from known manners, means, techniques and procedures by practitioners of the art to which the invention belongs.
- the term “at least” followed by a number is used herein to denote the start of a range beginning with that number (which may be a ranger having an upper limit or no upper limit, depending on the variable being defined). For example, “at least 1” means 1 or more than 1.
- the term “at most” followed by a number is used herein to denote the end of a range ending with that number (which may be a range having 1 or 0 as its lower limit, or a range having no lower limit, depending upon the variable being defined). For example, “at most 4” means 4 or less than 4, and “at most 40%” means 40% or less than 40%.
- a range is given as “(a first number) to (a second number)” or “(a first number)-(a second number)”, this means a range whose lower limit is the first number and whose upper limit is the second number.
- 25 to 100 should be interpreted to mean a range whose lower limit is 25 and whose upper limit is 100.
- every possible subrange or interval within that range is also specifically intended unless the context indicates to the contrary.
- ranges for example, if the specification indicates a range of 25 to 100 such range is also intended to include subranges such as 26-100, 27-100, etc., 25-99, 25-98, etc., as well as any other possible combination of lower and upper values within the stated range, e.g., 33-47, 60-97, 41-45, 28-96, etc.
- integer range values have been used in this paragraph for purposes of illustration only and decimal and fractional values (e.g., 46.7-91.3) should also be understood to be intended as possible subrange endpoints unless specifically excluded.
- the defined steps can be carried out in any order or simultaneously (except where context excludes that possibility), and the method can also include one or more other steps which are carried out before any of the defined steps, between two of the defined steps, or after all of the defined steps (except where context excludes that possibility).
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- Materials Engineering (AREA)
- Inorganic Chemistry (AREA)
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Abstract
A pouch cell includes a copper foil forming a pouch, an active material layer adjacent to the copper foil inside the pouch forming a cathode with the copper, and a lithium-based anode inside the pouch. The cell includes a separator interposing the one active material layer and the lithium-based anode, and an electrolyte. In other embodiments, the active material forms an anode with the copper and the cathode is a lithium-based cathode.
Description
- This application claims the benefit of U.S. Ser. No. 16/663,046, filed Oct. 24, 2019, which in turn claimed the benefit of U.S. provisional patent application Ser. No. 62/749,950, filed on Oct. 24, 2018, and incorporates such priority applications by reference into this disclosure as if fully set out at this point.
- This disclosure relates to battery technology in general and, more particularly, to improved construction methods for battery cells.
- The invention of the present disclosure, in one aspect thereof, comprises a pouch cell including a copper foil forming a pouch, an active material layer adjacent to the copper foil inside the pouch forming a cathode with the copper, and a lithium-based anode inside the pouch. The cell also includes a separator interposing the one active material layer and the lithium-based anode, and an electrolyte. In other embodiments, the active material forms an anode with the copper and the cathode is a lithium-based cathode.
- In some embodiments, the active material comprises an acidified metal oxide. The active material may be applied in at least one layer inside the pouch and has a density of about 6.49 mg/cm2. The separator may comprise a pouch containing the lithium-based anode. The separator may be polypropylene.
- The pouch cell may comprises a unitary segment of copper foil folded to create the pouch. The segment of copper foil may have a folded edge forming a bottom of the pouch and opposite sides of the pouch adjacent to the folded bottom edge are sealed together.
- The cell may include a first terminal tab electrically connected to the lithium-based anode and accessible outside the pouch. A second terminal tab may be electrically connected to the copper foil pouch. The lithium-based anode may be a lithium foil. In some cases, the lithium-based anode consists of metallic lithium.
- The pouch cell may have an insulating layer applied to an outside of the copper foil pouch. The insulating layer may comprise polyisobutylene.
- The invention of the present disclosure, in another aspect thereof, comprises a method of forming a battery cell. The method includes preparing a copper foil pouch, lining an interior portion of the copper foil pouch with an active material to create a cathode pouch, providing a lithium-based foil anode surrounded by a separator inside the pouch. An electrolyte is be provided inside the pouch. The pouch is sealing upon completion.
- In some embodiments, the method includes attaching a first electrical tab as a terminal to the cathode inside the pouch and routing the electrical tab to outside the pouch. The method may include affixing a second electrical tab to the copper foil pouch. Coating an outside of the copper foil pouch with an insulating material may also form part of the method.
- The invention of the present disclosure, in another aspect thereof, comprises a battery cell having a copper foil pouch having an opening end and a folded end and opposite sealed-together sides. The cell includes an active material lining the copper foil pouch, a segment of lithium foil inside a separator inside the pouch, and a first terminal affixed to the lithium foil and accessibly outside the pouch. The copper foil pouch contains an electrolyte and is sealed at the opening end and encloses the lithium foil, separator, and electrolyte inside the pouch, and provides a working voltage between the copper pouch and the first terminal.
- In some embodiments, the copper foil has a second terminal affixed thereto and provides the working voltage between the first and second terminals. Some embodiments include an electrically insulating polymer coating applied to an outside of the copper foil pouch.
-
FIG. 1 is an outside view of a pouch cell according to aspects of the present disclosure. -
FIG. 2 is an exploded perspective view of the pouch cell ofFIG. 1 . -
FIG. 3 is a top down view of a pouch cell under construction according to aspects of the present disclosure. -
FIG. 4 is a top down view of a the pouch cell ofFIG. 2 after further construction according to aspects of the present disclosure. -
FIG. 5 is a flow chart of a pouch cell production process according to aspects of the present disclosure. - In various embodiments, the present disclosure describes construction of pouch-type cells based upon various battery chemistries. The present disclosure is not intended to be specific to any chemistry (unless so claimed). However, the methods and constructions used herein are known to function well with acidified metal oxides as active electrode materials such as those described in U.S. Pat. No. 9,786,910 to Johnson, et al. (herein incorporated by reference), and related materials.
- Referring now to
FIG. 1 an outside view of apouch cell 100 according to aspects of the present disclosure is shown. The pouch cell comprises anouter pouch 102, which may comprise a metallic foil such as a copper foil. In further embodiments, the copper foil may be replaced with a polymer metalized film. Such film may also be coated with an outer insulative layer as described below. A mesh current collector (not shown) may also be used, along with sufficient outer insulative coating(s). - The
outer pouch 102 may be fully or partially coated of covered with aninsulating coating 108. Thecoating 108 may be configured to conform to the shape of thepouch 102 and may be sufficiently malleable not to flake or crack from movement of deflection of thepouch 102. In one embodiment, to form thecoating 108 on thepouch 102, a butyl rubber coating is applied such as polyisobutylene (PIB). A 2% PIB/Hexane solution may be prepared, and thepouch 102 dipped into the same resulting in a PIBouter coating 108 that prevents shorting and electrically isolates components such asterminals PIB coating 108 thus forms a case for thepouch cell 100 that conforms to the shape of thepouch 102. - The
coating 108 on thecopper foil pouch 102 may be transparent or may be colored by various dyes, pigments, paints, or the like. Insulators other than PIB may also be used for thecoating 108. Polymers dispersed in solvents may form the basis of aninsulative coating 108 for thecopper foil pouch 102. In some embodiments, thecoating 108 is sprayed or painted on, and possibly actively or passively cured. - The
pouch 100 is provided with an externallyaccessible cathode terminal 104 and an externallyaccessible anode terminal 106. These may also be denoted apositive terminal 104 and anegative terminal 106. Theterminals terminals terminals terminals cell 100 as a subcomponent of a completed battery, or to a specific load. - Referring now to
FIG. 2 an exploded perspective view of thepouch cell 100 ofFIG. 1 is shown. The exploded view ofFIG. 2 illustrates various additional internal components of thecell 100. Thepouch 102, as illustrated, comprises a layer of copper foil having afold 202 near the middle thereof. Thefold 202 in the copper foil creates two halves of thepouch 102 withopposite sides fold 202 is apouch mouth end 208. On the inner side of the copper foil of thepouch 102 is anactive material layer 210. Theactive material layer 210 may be on both inner sides of thepouch 102 and, in contact with the copper foil form a cathode. - The
active material 210 may be deposited as a slurry that is then cured or dried. Theactive material 210 may be spray applied. In some embodiments, layers of material are applied, possibly with carbon layers between. For purposes of the present disclosure, an active material is one that, when placed in contact with the copper foil of thepouch 102, a cathodic structure will result that may be used with an electrolyte, separator, and anode to function as a battery cell. In other embodiments, theactive material 210 forms an anode with the copper and the cathode is a lithium-based cathode. - In particular embodiments, the
active material 210 is a surface-functionalized, acidified metal oxide, as described in U.S. Pat. No. 9,786,910. Theactive material 210 may comprise, for example, at least one solid metal oxide nanomaterial including a surface that is acidic but not superacidic, the surface having a pH<5 when re-suspended, after drying, in water at 5 wt % and a Hammett function H0>−12. In some embodiments, theactive material 210 may be said to comprise a solid metal oxide nanomaterial being in a form MmOx/G, where Mm is a metal, Ox is total oxygen, MmOx is a metal oxide, G is at least one electron-withdrawing surface group, and “/” makes a distinction between the metal oxide and the electron-withdrawing surface group, the battery electrode solid metal oxide nanomaterial having a pH<5 when re-suspended, after drying, in water at 5 wt % and a Hammett function H0>−12, at least on its surface. - It should also be understood that cells may be constructed based on the present disclosure that do not utilize acidic metal oxides as active materials.
- The size, volume, or area of the cathode
active material 210 may vary, but overall size corresponds to overall capacity of thecell 100. Additionally, in various illustrated embodiments, the total size of the cathode is reflected in the folding or doubling over during assembly of the completed cell. The thickness of active material may vary. In one embodiment, the active material is applied at a density of 6.49 mg/cm2. The ends and sides of thecopper foil pouch 102 may be left free of active material to allow the foil to be folded and sealed (e.g., the foldedend 202, themouth end 208, and or theopposite sides active material 210 applied thereon. - In order to seal or close the pouch 102 a single-piece or multi-piece
adhesive strip 212 may bind the edges of the two halves of thepouch 102 together. Theadhesive strip 212 may be tape, glue, or anther adhesive. Theadhesive strip 212 may be chosen such that thepouch 102 will seal to contain electrolytes and other internal battery components without dissolution of theadhesive strip 212. In some embodiments, the copper foil of thepouch 102 may be cut at thefold 202 to allow easier application of theadhesive strip 212. - Contained within the
pouch 102 may be aseparator 214 interposing theactive material 210 and ananode 216. Theseparator 214 may be suitable to the internal chemistry of thecell 100. In some embodiments, theseparator 214 comprises Targray polypropylene or polyethylene. In some embodiments, theseparator 214 may be a folded material or formed into a pouch such that is completely enclosed theanode 216 and insulates it from electrical contact with theactive material 210 acting as a cathode. A segment of adhesive tape (not shown) or other device may secure theseparator 214 in place around theanode 216 during pouch/cell assembly. The tape or other insulating adhesive may also serve to prevent contact between theanode tab 106 and thecopper foil 102 during assembly. - The
anode 216 may be a lithium-based material. Ifactive materials 210 are used corresponding to those described in U.S. Pat. No. 9,786,910, a pure lithium foil may safely be used as theanode 216. In other embodiments, other known lithium-based compounds may be used. In some embodiments, theanode 216 comprises lithium foil having a thickness of about 1 mm. - A
compatible electrolyte 220 may complete thecell 100 and may be inserted into thepouch 102 prior to final sealing of thepouch 102. - Referring now to
FIG. 3 , a top down view of thepouch cell 100 as it would appear under construction according to aspects of the present disclosure is shown. Thepouch 102 is unfolded (or not yet folded) onfold 202 withopposite sides Active material 210 has been applied to the inner surface of thepouch 102 with a margin allowing for sealing of thepouch 102. It may be necessary to remove active material from an area around thefold 202 as shown by 302. - Referring now to
FIG. 4 , a top down view of a the pouch cell ofFIG. 2 after further construction according to aspects of the present disclosure is shown. Here active material 110 has been removed from thearea 302 around thefold 202. This may be accomplished by application and removal of masking tape that may pull active material away from thepouch 102. In other embodiments, a suitable solvent or other method may be used. A portion of theadhesive strip 212 may be applied alongsides pouch 102 is folded atfold 202. - In some embodiments the
mouth 208 of thepouch 102 is folded together and sealed. This may be with or without a portion of theadhesive strip 212 or another adhesive to seal the fold. - Referring now to
FIG. 5 , is aflow chart 500 of a pouch cell production process according to aspects of the present disclosure is shown. The method as illustrated byflow chart 500 is exemplary only. If different materials or construction methods are employed, the construction method may be adapted accordingly. Atstep 510 thecopper foil pouch 102 is prepared. Atstep 512 theactive material 210 is applied. This may include ensuring proper clearance at the margins to be sealed. Atstep 514 the foil is folded and sealed (e.g., with adhesive) as apouch 102 with anopen end 208. A tab or terminal 104 may be affixed to the foil atstep 516. - At step 518 a terminal 106 is affixed to an
anode 216. The anode is wrapped in aseparator 214 atstep 520. Atstep 522 the anode is placed in thepouch 102. Electrolyte may be added atstep 524. Theopen end 208 of thepouch 102 may be sealed by folding, application of adhesive, or other methods atstep 526. Finally, atstep 528, thepouch 102 may have coating 108 applied thereto to insulate thepouch 102. - A pouch cell was constructed as described above. The completed pouch cell was tested to confirm that the PIB coating provided adequate electrical isolation and resistance to internal components of the pouch cell. The completed cell was also used to power loads such as LEDs.
- Additional cells of varying sizes and capacities have been produced with similar positive results. A pouch cell having an active material area as small as 2 cm×2 cm per side, surrounding a 1 mm thick 1.8 cm×1.8 cm lithium foil anode has also been shown to effectively power loads such as LEDs.
- It is to be understood that the terms “including”, “comprising”, “consisting” and grammatical variants thereof do not preclude the addition of one or more components, features, steps, or integers or groups thereof and that the terms are to be construed as specifying components, features, steps or integers.
- If the specification or claims refer to “an additional” element, that does not preclude there being more than one of the additional element.
- It is to be understood that where the claims or specification refer to “a” or “an” element, such reference is not be construed that there is only one of that element.
- It is to be understood that where the specification states that a component, feature, structure, or characteristic “may”, “might”, “can” or “could” be included, that particular component, feature, structure, or characteristic is not required to be included.
- Where applicable, although state diagrams, flow diagrams or both may be used to describe embodiments, the invention is not limited to those diagrams or to the corresponding descriptions. For example, flow need not move through each illustrated box or state, or in exactly the same order as illustrated and described.
- Methods of the present invention may be implemented by performing or completing manually, automatically, or a combination thereof, selected steps or tasks.
- The term “method” may refer to manners, means, techniques and procedures for accomplishing a given task including, but not limited to, those manners, means, techniques and procedures either known to, or readily developed from known manners, means, techniques and procedures by practitioners of the art to which the invention belongs.
- The term “at least” followed by a number is used herein to denote the start of a range beginning with that number (which may be a ranger having an upper limit or no upper limit, depending on the variable being defined). For example, “at least 1” means 1 or more than 1. The term “at most” followed by a number is used herein to denote the end of a range ending with that number (which may be a range having 1 or 0 as its lower limit, or a range having no lower limit, depending upon the variable being defined). For example, “at most 4” means 4 or less than 4, and “at most 40%” means 40% or less than 40%.
- When, in this document, a range is given as “(a first number) to (a second number)” or “(a first number)-(a second number)”, this means a range whose lower limit is the first number and whose upper limit is the second number. For example, 25 to 100 should be interpreted to mean a range whose lower limit is 25 and whose upper limit is 100. Additionally, it should be noted that where a range is given, every possible subrange or interval within that range is also specifically intended unless the context indicates to the contrary. For example, if the specification indicates a range of 25 to 100 such range is also intended to include subranges such as 26-100, 27-100, etc., 25-99, 25-98, etc., as well as any other possible combination of lower and upper values within the stated range, e.g., 33-47, 60-97, 41-45, 28-96, etc. Note that integer range values have been used in this paragraph for purposes of illustration only and decimal and fractional values (e.g., 46.7-91.3) should also be understood to be intended as possible subrange endpoints unless specifically excluded.
- It should be noted that where reference is made herein to a method comprising two or more defined steps, the defined steps can be carried out in any order or simultaneously (except where context excludes that possibility), and the method can also include one or more other steps which are carried out before any of the defined steps, between two of the defined steps, or after all of the defined steps (except where context excludes that possibility).
- Further, it should be noted that terms of approximation (e.g., “about”, “substantially”, “approximately”, etc.) are to be interpreted according to their ordinary and customary meanings as used in the associated art unless indicated otherwise herein. Absent a specific definition within this disclosure, and absent ordinary and customary usage in the associated art, such terms should be interpreted to be plus or minus 10% of the base value.
- Thus, the present invention is well adapted to carry out the objects and attain the ends and advantages mentioned above as well as those inherent therein. While the inventive device has been described and illustrated herein by reference to certain preferred embodiments in relation to the drawings attached thereto, various changes and further modifications, apart from those shown or suggested herein, may be made therein by those of ordinary skill in the art, without departing from the spirit of the inventive concept the scope of which is to be determined by the following claims.
Claims (10)
1. A method of forming a battery cell comprising:
preparing a pouch made of copper foil, the copper foil being a unitary segment of copper foil having a folded edge forming a bottom of the pouch and equal-sized opposite halves of the pouch adjacent to the folded edge being sealed sides;
lining an interior portion of the pouch with an active material including an acidified metal oxide to create a cathode;
providing a lithium-based anode surrounded by a separator inside the pouch;
providing an electrolyte inside the pouch; and
sealing the pouch.
2. The method of claim 1 , further comprising adding an insulating layer outside the pouch including polyisobutylene.
3. The method of claim 1 , further comprising attaching a first terminal tab to the cathode inside the pouch and routing the first terminal tab to outside the pouch.
4. The method of claim 1 , further comprising attaching a second terminal tab to the lithium-based anode inside the pouch and routing the second terminal tab to outside the pouch.
5. The method of claim 1 , wherein the active material is applied in at least one layer inside the pouch with a density of about 6.49 mg/cm2.
6. The method of claim 1 , wherein the separator comprises a pouch containing the lithium-based anode.
7. The method of claim 1 , wherein the separator comprises polypropylene.
8. The method of claim 1 , wherein the lithium-based anode is a lithium foil.
9. The method of claim 1 , wherein the lithium-based anode consists of metallic lithium.
10. The method of claim 1 , further comprising providing the battery cell.
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US16/663,046 US11482752B2 (en) | 2018-10-24 | 2019-10-24 | Polymer dipped pouch cell |
US18/049,079 US20230078781A1 (en) | 2018-10-24 | 2022-10-24 | Polymer dipped pouch cell |
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WO2024122908A1 (en) * | 2022-12-05 | 2024-06-13 | 주식회사 엘지에너지솔루션 | Battery module, and battery pack and vehicle comprising same |
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JP6036811B2 (en) * | 2012-04-13 | 2016-11-30 | 日本電気株式会社 | Positive electrode active material for secondary battery and secondary battery using the same |
KR101966182B1 (en) * | 2014-07-16 | 2019-04-05 | 주식회사 아모그린텍 | Flexible battery using the flexible pouch |
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2019
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CA3117215A1 (en) | 2020-04-30 |
JP2022517468A (en) | 2022-03-09 |
EP3871287A1 (en) | 2021-09-01 |
CN112913063A (en) | 2021-06-04 |
WO2020086887A1 (en) | 2020-04-30 |
EP3871287A4 (en) | 2022-08-03 |
KR20210078543A (en) | 2021-06-28 |
US11482752B2 (en) | 2022-10-25 |
US20200136106A1 (en) | 2020-04-30 |
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