Classifications

• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M10/00—Secondary cells; Manufacture thereof
  • H01M10/60—Heating or cooling; Temperature control
  • H01M10/65—Means for temperature control structurally associated with the cells
  • H01M10/655—Solid structures for heat exchange or heat conduction
  • H01M10/6553—Terminals or leads
• • 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
  • H01M50/543—Terminals
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M10/00—Secondary cells; Manufacture thereof
  • H01M10/05—Accumulators with non-aqueous electrolyte
  • H01M10/052—Li-accumulators
  • H01M10/0525—Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodes; Lithium-ion batteries
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M10/00—Secondary cells; Manufacture thereof
  • H01M10/60—Heating or cooling; Temperature control
  • H01M10/61—Types of temperature control
  • H01M10/617—Types of temperature control for achieving uniformity or desired distribution of temperature
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M10/00—Secondary cells; Manufacture thereof
  • H01M10/60—Heating or cooling; Temperature control
  • H01M10/64—Heating or cooling; Temperature control characterised by the shape of the cells
  • H01M10/647—Prismatic or flat cells, e.g. pouch cells
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M10/00—Secondary cells; Manufacture thereof
  • H01M10/60—Heating or cooling; Temperature control
  • H01M10/65—Means for temperature control structurally associated with the cells
  • H01M10/651—Means for temperature control structurally associated with the cells characterised by parameters specified by a numeric value or mathematical formula, e.g. ratios, sizes or concentrations
• • 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
  • H01M50/116—Primary casings; Jackets or wrappings characterised by the material
• • 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
• • 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
  • H01M50/178—Arrangements of electric connectors penetrating the casing adapted for the shape of the cells for pouch or flexible bag 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
  • H01M50/531—Electrode connections inside a battery casing
  • H01M50/533—Electrode connections inside a battery casing characterised by the shape of the leads or tabs
• • 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
  • H01M50/531—Electrode connections inside a battery casing
  • H01M50/534—Electrode connections inside a battery casing characterised by the material of the leads or tabs
• • 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
  • H01M50/531—Electrode connections inside a battery casing
  • H01M50/54—Connection of several leads or tabs of plate-like electrode stacks, e.g. electrode pole straps or bridges
• • 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
  • H01M50/543—Terminals
  • H01M50/547—Terminals characterised by the disposition of the terminals on the cells
  • H01M50/55—Terminals characterised by the disposition of the terminals on the cells on the same side of the cell
• • 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
  • H01M50/543—Terminals
  • H01M50/552—Terminals characterised by their shape
  • H01M50/553—Terminals adapted for prismatic, pouch or rectangular cells
  • H01M50/557—Plate-shaped terminals
• • 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
  • H01M50/543—Terminals
  • H01M50/562—Terminals characterised by the material
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M10/00—Secondary cells; Manufacture thereof
  • H01M10/05—Accumulators with non-aqueous electrolyte
  • H01M10/058—Construction or manufacture
  • H01M10/0585—Construction or manufacture of accumulators having only flat construction elements, i.e. flat positive electrodes, flat negative electrodes and flat separators
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M4/00—Electrodes
  • H01M4/02—Electrodes composed of, or comprising, active material
  • H01M4/64—Carriers or collectors
  • H01M4/66—Selection of materials
  • H01M4/661—Metal or alloys, e.g. alloy coatings
• • 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
• • 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
  • Y10T29/49115—Electric battery cell making including coating or impregnating

Definitions

• the present invention generally relates to an electrochemical battery cell. More particularly, the present invention relates to designs of power terminals of an electrochemical battery cell.
• An electrochemical battery cell can be, for example, a prismatic cell or a cylindrical cell.
• a prismatic cell e.g., a prismatic lithium ion cell
• a conventional prismatic battery cell has two power terminals or extension tabs (a positive terminal and a negative terminal) disposed at one end or two opposite ends of the cell. Extension tabs can extend from current collecting tabs attached to the electrodes.
• the positive and negative extension tabs are typically made from different materials. For example, the extension tabs are often made of aluminum (positive) and copper (negative) or nickel (negative).
• FIGS. 1A, 1 B, and 1 C illustrate prior art prismatic cells 102, 104, and 106, respectively. As shown, the dimensions of the extension tabs (terminals 112a, 112b for cell 102, terminals 114a, 114b for cell 104, and terminals 116a, 116b for cell 106) are roughly identical for each cell.
• a battery cell with asymmetric power terminals is provided.
• the sizes of the positive terminal and the negative terminal (and the corresponding current collecting tabs) are selected to be proportional to the electrical resistivity and thermal conductivity of their respective materials of construction. This design reduces temperature differences within the electrochemical cell. The maximum temperature within the electrochemical cell (i.e., the temperature of the hottest point in the cell) is also reduced.
• a prismatic cell includes a plurality of positive electrodes and negative electrodes.
• a power terminal or extension tab attached to the positive electrodes can be made from a first conductive material that is comparable with the electrical and chemical properties of the positive electrode, and a power terminal or extension tab attached to the negative electrodes can be made from a second conductive material that is comparable with the electrical and chemical properties of the negative electrode.
• the positive extension tab can be aluminum and the negative extension tab can be nickel or copper.
• the cross- sectional area of the negative extension tab can be selected to be about 2/3 of the cross-sectional area of the positive extension tab.
• the thickness of the positive and negative extension tabs are identical, while the width of the negative extension tab is selected to be about 2/3 of the width of the positive extension tab.
• the prismatic cell can be, for example, a lithium ion cell.
• an electrochemical cell having a plurality of positive and negative electrode sheets.
• the electrode sheets each have current collecting tabs.
• a positive terminal or extension tab extends from the current collecting tabs of the positive electrode sheets, and a negative terminal or extension tab extends from the current collecting tabs of the negative electrode sheets.
• a cross sectional area of the positive extension tab is different than a cross sectional area of the negative extension tab.
• the electrode sheets include an active material on the sheets' surfaces, while the portions of the electrode sheets forming the current collecting tabs are not covered by the active material.
• a lithium battery comprising a plurality of positive electrode sheets having current collecting tabs, and a plurality of negative electrode sheets having current collecting tabs.
• An electrolyte of the battery is in ionic contact with the positive and negative electrode sheets.
• a positive terminal or extension tab is extended from the current collecting tabs of the positive electrode sheets, and a negative terminal or extension tab is extended from the current collecting tabs of the negative electrode sheets.
• a pouch encloses the positive and negative electrode sheets. The pouch is sealed around the positive and negative electrode sheets such that the positive extension tab and the negative extension tab extend from inside to outside of the pouch.
• a cross sectional area of the positive extension tab is different than a cross sectional area of the negative terminal.
• a method of making an electrochemical cell comprises providing a plurality of positive electrode sheets with current collecting tabs, and providing a plurality of negative electrode sheets with current collecting tabs.
• the method further includes extending a positive terminal or extension tab from the current collecting tabs of the positive electrode sheets; and extending a negative terminal or extension tab from the current collecting tabs of the negative electrode sheets.
• a cross sectional area of the positive extension tab is selected to be different than a cross sectional area of the negative extension tab based on properties of the materials used for the extension tabs, such as electrical resistively and thermal conductivity.
• dimensions of the positive and negative extension tabs comprise a width and thickness.
• the width of the positive extension tab may be different than the width of the negative extension tab.
• the thickness of the positive extension tab may be different than the thickness of the negative extension tab.
• the current collecting tabs of the positive electrode sheets are welded together to provide a welded portion.
• the current collecting tabs of the negative electrode sheets are also welded together to provide another welded portion.
• the positive extension tab is welded at the welded portion of the positive current collecting tabs, and the negative extension tab is welded at the welded portion of the negative current collecting tabs.
• a sealant material can be disposed on the positive extension tab and the negative extension tab to form a seal with the pouch.
• the pouch material may comprise, for example, laminated layers comprising at least one of polyethylene, nylon, and aluminum foil.
• the positive extension tab is disposed on an outermost one of the current collecting tabs of the positive electrode sheets; and the negative extension tab is disposed on an outermost one of the current collecting tabs of the negative electrode sheets.
• the positive extension tab may comprise aluminum and the negative extension tab copper, such that the positive extension tab is approximately 60 mm thick and the negative extension tab is approximately 40 mm thick.
• a separator sheet is interposed between the positive electrode sheets and the negative electrode sheets.
• the separator sheet may be a continuous sheet that is folded between the positive electrode sheets and the negative electrode sheets.
• the positive extension tab has a predetermined cross sectional area
• the negative extension tab has a different cross sectional area, such that during use the positive extension tab has a first temperature and the negative extension tab has a second temperature to form an optimal temperature difference between the positive extension tab temperature and the negative extension tab temperature.
• the optimal temperature difference will not be decreased any further by changing the ratio of the cross sectional area of the positive extension tab to the cross sectional area of the negative extension tab.
• FIG.1 A is a front view of a conventional prismatic battery cell.
• FIG.1 B is a front view of another conventional prismatic battery cell.
• FIG.1 C is a front view of yet another conventional prismatic battery cell.
• FIG. 2A is a front view of a prismatic battery cell according to various embodiments.
• FIG. 2B is a side view of the prismatic battery cell shown in FIG. 2A.
• FIG. 3 is a diagram illustrating cathode and anode sheets and attached current collecting tabs of a prismatic battery cell according to various embodiments.
• FIG. 4 is a diagram illustrating a series of cathode and anode sheets disposed on a separator sheet before being assembled into a prismatic battery cell.
• FIG. 5 includes front and side views of extension tabs for cathode and anode sheets of a prismatic battery cell according to various embodiments.
• FIG. 6 is a diagram illustrating welding locations of a tab assembly of a prismatic battery cell, according to various embodiments.
• FIG. 7 is a diagram illustrating a top seal of a prismatic battery cell according to various embodiments.
• FIG. 8 is a diagram illustrating a side seal of a prismatic battery cell according to various embodiments.
• FIG. 9 is a diagram illustrating various components of a prismatic battery cell and its tab assembly, according to various embodiments.
• FIGS. 10-16 are diagrams illustrating temperature distributions for various prismatic battery cell designs.
• FIG. 17 is a diagram illustrating a finite element model used for simulating temperature changes of a battery cell.
• FIG. 18 is a chart illustrating temperature changes at various points of a prismatic battery cell over time.
• FIG. 19 is a chart illustrating temperature and voltage changes at various points of a prismatic battery cell over time.
• Battery cells with asymmetric power terminals are described. Some embodiments provide cells having terminals or extension tabs that are sized proportional to their respective electrical and thermal properties. This allows the temperature at the hottest point in the cell, as well as temperature gradient of the cell (i.e., difference between the maximum temperature and the minimum temperature in the cell) to be reduced. Because cell performance and safety are generally limited by the temperature of the hottest point in the cell, cells having extension tabs that are sized proportional to their respective electrical and thermal properties allow cycling at increased rates, increased cell lifetime, increased cell safety, and/or some combination of these effects.
• FIG. 2A is a front view of a prismatic battery cell 200 according to various embodiments.
• FIG. 2B is a side view of the prismatic battery cell shown in FIG. 2A.
• Cell 200 has a positive power terminal or extension tab 202a and a negative power terminal or extension tab 202b that are asymmetric in size.
• the asymmetric terminals (which extend from current collecting tabs of the electrode sheets) can be adapted to virtually any cell chemistry that uses relatively thin electrodes.
• the thermal features of asymmetric extension tabs are useful for cells that are designed to operate at relatively high rates. Typical cell chemistries that run at high rates might be nickel / metal hydride or nickel / cadmium.
• Cell 200 can be, for example, a lithium ion cell.
• extension tab 202a can be attached to current collecting tabs of the positive electrodes
• extension tab 202b can be attached to current collecting tabs of the negative electrodes.
• Current collecting tabs of the positive electrodes can be made from aluminum
• current collecting tabs of the negative electrodes can be made from copper or nickel.
• the materials from which current collectors and extension tabs of electrochemical cells are constructed are generally limited to those which are electrochemically compatible with the electrolyte and voltage of the cell.
• the material of the positive current collectors, positive tabs and any other conductive elements at the positive electrode potential that are wetted with electrolyte should be resistant to electrochemical corrosion at the potential of the positive electrode potential.
• Materials that tend to be resistant to electrochemical corrosion at the positive electrode potential of a lithium ion cell include aluminum, molybdenum, titanium, and certain stainless steel alloys, for example.
• aluminum has the highest electrical and thermal conductivity to cost ratios, making it an exemplary material for use at positive electrode potential.
• the material of the negative current collectors, negative tabs and any other conductive elements at the negative electrode potential that are wetted with electrolyte should be resistant to alloying with lithium at the negative electrode potential.
• Materials that tend to be resistant to alloying with lithium at the negative potential of the lithium ion cell include copper, nickel and iron, for example. Of these materials, copper has the best electrical and thermal conductivities, making it an exemplary material for use at the negative electrode potential in a lithium ion cell.
• extension tabs 202a and 202b are not identical in size.
• the width of the negative extension tab 202b can be selected to be approximately 2/3 of the width of the positive extension tab 202a, while the thickness of the extension tabs can be identical.
• the cross-sectional area of the negative extension tab 202b is also approximately 2/3 of the cross- sectional area of the positive extension tab 202a.
• extension tabs 202a and 202b are made from materials other than aluminum, copper, or nickel, different dimensions for the extension tabs can be selected to reduce maximum temperature and temperature gradient of the cell.
• the cross-sectional area of the extension tabs is a determining factor for temperatures of the extension tabs, which can affect the maximum temperature and temperature gradient of the cell. If the thicknesses of the two extension tabs are selected to be identical, the width of the extension tabs can be adjusted to achieve an optimal effect. However, the thickness of the two terminals need not be selected to be identical.
• FIG. 3 is a diagram illustrating the cathode and anode sheets 302a, 302b and attached current collecting tabs 304a, 304b of a prismatic battery cell according to some embodiments.
• the dimensions of the electrode sheets can have any range that will provide the desired thermal and electrical properties, and that will be compatible with the volume requirements (e.g., available space) of the cell.
• the cathode sheets can be approximately 143 mm wide and 198 mm long, and the anode sheets can be approximately 145 mm wide and 200 mm long.
• Current collecting tab 304b as depicted has a width that is approximately 2/3 of the width of current collecting tab 304a.
• the width of current collecting tab 304a can be selected to be approximately 56.5 mm, and the width of current collecting tab 304b can be selected to be approximately 36.0 mm.
• the current collecting tabs may be cut during the manufacturing process to provide a suitable height.
• the electrode sheets 302a comprise a first active material 306a as known in the art.
• the current collecting tabs 304a of the electrode sheets 302a sheets are extended portions of the electrodes sheets 302a that are not covered by the active material 306a.
• the electrode sheets 302b comprise an active material 306b.
• the current collecting tabs 304b of the negative electrode sheets 302b are extended portions of the negative electrodes sheets 302b that are not covered by the material 306b.
• FIG. 4 is a diagram illustrating a series of cathode and anode sheets (e.g., 302a, 302b) disposed on a portion of a separator sheet 404 before being assembled into a prismatic battery cell.
• the separator sheet 404 with electrode sheets (e.g., 302a, 302b) can be folded horizontally, e.g., in an accordion pleat, so that the electrode sheets are stacked on top of one another and separated by separator sheet 404. This folding process can be referred to as stack-winding.
• the relative positions of electrodes 302a, 302b are selected for proper stacking and alignment of the electrodes between separator sheets.
• the dimensions of the separator sheet can have any range that is necessary to separate the electrodes, and that will be compatible with the volume requirements (e.g., available space) of the cell. For example, assuming that the electrodes are 143-145 mm wide, the separator sheet can be approximately 206 mm wide and 0.025 mm thick, and the distances between the electrodes when placed on the separator sheet can be approximately 145 mm.
• the relative positions of current collecting tabs (e.g., tab 304b) on anode sheets (e.g., sheet 302b) are formed so that the tabs will be aligned with one another vertically after stack-winding.
• the positions of current collecting tabs (e.g., tab 304a) on cathode sheets (e.g., sheet 302a) are also selected so that the tabs are aligned vertically after stack-winding.
• the inner components of the battery cell e.g., electrodes and separator sheet
• the inner components can be hermetically sealed.
• the inner components can be sealed within an enclosure made of a pouch material.
• a typical cell pouch material is comprised of laminated layers of polyethylene, nylon, and aluminum foil. However, any other suitable enclosure can be used to seal the inner components of the cell.
• Extension tabs are welded or otherwise affixed to the current collecting tabs.
• the extension tabs may include a strip of material for sealing purposes as discussed below in more detail.
• FIG. 5 shows front and side views of extension tabs 308a, 308b attached to current collecting tabs 304a, 304b of the positive and negative electrode sheets 302a, 302b respectively.
• the dimensions of the extension tabs 308a, 308b can have any range that will provide the desired thermal and electrical properties, and that will be compatible with the volume requirements (e.g., available space) of the cell.
• the thickness of the extension tabs 308a, 308b can be approximately 0.4 mm.
• Sealing strips 504a, 504b can be disposed across the middle of extension tabs 308a, 308b respectively. The strips 504a, 504b are used for sealing the inner components of the battery cell, as will be explained in connection with FIG. 7.
• FIG. 6 is a diagram illustrating the dimensions and welding locations of the tab assembly of the prismatic battery cell.
• FIG. 6 shows positions of the current collecting tabs 304a, 304b and extension tabs 308a, 308b after stack winding.
• Extension tabs 308a, 308b have strips 504a, 504b attached as previously shown.
• Current collecting tabs 304a, 304b and extension tabs 308a, 308b respectively have welding sections 604a, 604b below strips 504a, 504b.
• the positive currently collecting tabs e.g., tabs 304a
• the negative current collecting tabs e.g., tabs 304b
• the extension tabs 308a, 308b are welded to the grouped current collecting tabs 304a, 304b respectively.
• bottoms 310a, 310b of extension tabs 308a, 308b overlap with the grouped current collecting tabs 304a, 304b, such that, for example, a single extension tab 308a extends from the grouped current collecting tabs 304a.
• a single extension tab 308b extends from the grouped current collecting tabs 304b.
• the cross sectional areas of the grouped current colleting tabs 304a, 304b, may also be different from each other to provide a suitable ratio in accordance with the invention.
• the current collecting tabs are welded together at the same time the extension terminals are welded to the current collecting tabs. This may be the case, for example, when ultrasonic welding methods employed as excitation from ultrasonic welding tend to damage other welds in the proximity of the weld being made. In another embodiment, it is not necessary to join the current collecting tabs and extension terminals all together at the same time and they can be attached in separate processes.
• the extension tabs are thin, flat tabs, such that the length and the width of the positive extension tab 308a are each at least 10 times the thickness of the positive extension tab 308a.
• the length and the width of the negative extension tab 308b are each at least 10 times the thickness of the negative extension tab 308b.
• the length dimension of the extension tabs 308a, 308b is shown in FIG. 6 as extending vertically and the width dimension extending horizontally.
• the thickness dimension of the extension tabs extends into the page of FIG. 6, and is also shown in the embodiment of Figure 2B.
• the length and the width of the positive extension tab are each at least 50 times the thickness of the positive extension tab, and the length and the width of the negative extension tab are each at least 50 times the thickness of the negative extension tab. In another embodiment, the length and the width of the positive extension tab are each at least 100 times the thickness of the positive extension tab, and the length and the width of the negative extension tab are each at least 100 times the thickness of the negative extension tab. As shown in FIG. 7, the pouch is sealed around the positive electrode sheets and the negative electrode sheets such that the positive extension tab 308a and the negative extension tab 308b extend outside of the pouch.
• FIG. 7 is a diagram illustrating a top seal 706 of the prismatic battery cell according to some embodiments.
• a portion of a cell enclosure or pouch 704 is shown.
• Cell enclosure 704 is used to enclose the inner components of the cell assembly.
• enclosure 704 can include two sheets of pouch material placed on the front and back side of the stacked electrodes seamed together at the edges to enclose and hermetically seal the stacked electrodes.
• Strips 504a, 504b can be made of a material that matches the pouch material of enclosure 704, so that when the top edges of the cell enclosure sheets are seamed together, the top edges can be firmly attached to the strips 504a, 504b (and therefore the tab assemblies) for the portions where they are separated by the tab assemblies.
• a top seal 706 can be formed across strips 504a, 504b respectively attached to extension tabs 308a, 308b.
• the width of the seal can be approximately 5 mm.
• the separator sheet 404 is shown between the electrode plates 302a, 302b.
• FIG. 8 is a diagram illustrating a side seal 804 of the prismatic battery cell formed by seaming together the side edges of enclosure sheets.
• the width of side seal 804 can be approximately 10 mm.
• FIGS. 7-8 illustrate the use of one type of cell enclosure, any other suitable types of cell enclosure can be used to hermetically seal the inner components of a cell assembly.
• FIG. 9 is a diagram showing various components of one example of a complete prismatic battery cell 200 according to some embodiments, including current collecting tabs 304a, 304b, extension tabs 308a, 308b, welding sections 604a, 604b, and strips 504a, 504b.
• FIGS. 10-16 are diagrams illustrating results of simulation performed for this purpose.
• FIGS. 10-16 illustrate temperature distributions for various prismatic battery cell designs.
• the diagrams are based on data obtained from 3D transient thermal analysis of prismatic cells having a 214 x 153 x 7.3 mm cell body.
• the thermal analysis can be based on simulations using computer models of the battery cells.
• a computer model can be a finite element model as shown in FIG. 17, in which the cell is separated into small tetrahedral thermal solid elements for analysis.
• certain heat generation and heat conducting properties can be selected for various parts of the battery cells.
• the positive tab is assumed to have a density of 2.7e+006 g/m ⁇ 3, specific heat of 0.904 J/gK, and thermal conductivity of 230 VWmK in the X, Y, and Z directions.
• the negative tab is assumed to have a density of 8.96e+006 g/m ⁇ 3, specific heat of 0.385 J/gK, and thermal conductivity of 385 VWmK in the X, Y, and Z directions. It is assumed that heat transfer from the cell takes place only on the large, flat surfaces of the cell to air by convection to an ambient temperature and through the end of the tabs by conduction to a fixed temperature of 35 degrees Celsius.
• the ambient temperature is assumed to be 35 degrees Celsius and the convection film coefficient is assumed to be 10W/m ⁇ 2K.
• FIGS. 10-16 provide front views of the cells for different designs that are modeled, including the cell body (e.g., cell body 1004 in FIG. 10) and the extension tabs (e.g., terminals 1006 in FIG. 10). The dimensions of the extension tabs are shown at the bottom of each diagram (e.g., at location 1008 in FIG. 10). Temperature of the battery cell across the battery cell after 60 seconds is depicted using temperature scales (e.g., scale 1002 in FIG. 10). For example, in FIG.
• region 1010a corresponds to the lower end of temperature scale 1002 and therefore has a temperature of approximately 31.9 degrees Celsius
• region 1010b corresponds to the higher end of temperature scale 1003 and therefore has a temperature of approximately 40.6 degrees Celsius.
• the minimum and maximum temperatures of the cell are also shown to the top left of the illustrated cells (e.g., location 1012 in FIG. 10).
• FIG. 10 shows that if the power terminals or extension tabs have identical sizes (50 mm), temperatures at the two terminals are different.
• the aluminum extension tab is approximately 50 mm wide, and the copper tab is approximately 50 mm wide, the temperatures at the two terminals are not uniform. This results in a temperature gradient.
• FIGS. 11 shows that when the aluminum tab is approximately 60 mm wide, and the copper tab is approximately 40 mm wide, the temperature gradient between the two terminals is reduced.
• the minimum temperature is approximately 31.9 degrees Celsius and the maximum temperature is approximately 38.5 degrees Celsius after 60 seconds. This results in a smaller temperature gradient and the temperature of the hottest point in the cell in FIG. 11 is smaller than the temperature of hottest point in the cell in FIG. 10.
• FIGS. 12 shows that when the aluminum tab is approximately 65 mm wide, and the copper tab is approximately 35 mm wide, the temperature gradient between the two terminals is altered. The minimum temperature is approximately 31.9 degrees Celsius and the maximum temperature is approximately 39.4 degrees Celsius after 60 seconds, thereby demonstrating a change in temperature based on a different cross section area ratio between the extension tabs.
• FIG. 13 shows that when the aluminum tab is approximately 63 mm wide, and the copper tab is approximately 37 mm wide. The minimum temperature is approximately 31.9 degrees Celsius and the maximum temperature is approximately 38.8 degrees Celsius after 60 seconds.
• FIGS. 14 shows that when the aluminum tab is approximately 62 mm wide, and the copper tab is approximately 38 mm wide, the maximum temperature is lowered with respect to that in FIGS. 12 and 13.
• FIGS. 15 and 16 show that when the aluminum tab is approximately 61 mm wide, and the copper tab is approximately 39 mm wide, the temperatures at the two terminals are approximately uniform after 60 seconds. This results in a smaller temperature gradient.
• the analyses whose results are shown in FIGS. 15 and 16 are identical with the exception of a different ASI selected for that in FIG. 16.
• the volumetric heat generation of the body of the cell is directly proportional to ASI.
• the significance of FIGS. 15 and 16 is that they show that exemplary embodiments of the invention have utility over a range of rates of heat generation as opposed to only at a single rate of heat generation.
• Fig 15 shows a max temp of 38.411.
• Fig 16 shows a max temp of 42.994 ("SMX" denotes the max temperature shown in the plot).
• FIG. 18 is a chart illustrating temperature changes at various points of a prismatic battery cell over time.
• the battery cell has a positive aluminum extension tab with a width of 61 mm and a negative copper extension tab with a width of 39 mm.
• the chart is based on data obtained from the thermal analysis described above.
• Line “Tcenter” shows temperature changes in the center of the cell body.
• Lines “Tnegtab” and “Tpostab” respectively show temperature changes in the center of the negative extension tab and the positive extension tab at the intersection with the cell body. As shown, temperature differences at these three locations are generally small.
• FIG. 19 is a chart illustrating temperature and voltage changes of a prismatic battery cell over time.
• the body of the cell has a dimension of 7.5 x 150 x 200 mm.
• the positive extension tab has a width of 56.5 mm, and the negative extension tab has a width of 36 mm. As shown, temperature at the positive extension tab is relatively close to temperature at the negative extension tab.
• embodiments of the present invention can also be applied to other battery cells such as cylindrical cells.
• the dimensions of the current collecting tabs or the extension tabs for the positive and negative terminals can also be made proportional to the electrical resistivity and thermal conductivity of their respective materials of construction, so that temperature gradient and/or maximum temperature are reduced. This would benefit the performance of the cylindrical cell in terms of battery life and safety.
• embodiments of the present invention can be applied to any electrochemical cell that uses relatively thin electrodes, which are typically designed to operate at relatively high rates. Examples of such cells include nickel / metal hydride cells and nickel / cadmium cells.

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• 2008
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