`
`1111111111111101111110101111111!!0!12113131111121,1))111111111111011011110111111
`
`(19) United States
`(12) Patent Application Publication (10) Pub. No.: US 2005/0233212 Al
`Oct. 20, 2005
`Kaun
`(43) Pub. Date:
`
`(54) HOUSING FOR ELECTROCHEMICAL
`DEVICES
`
`(52) U.S. Cl.
`
` 429/176; 429/53; 429/185;
`429/175
`
`(76)
`
`Inventor: Thomas D. Kaun, New Lenox, IL (US)
`
`Correspondence Address:
`FOLEY & LARDNER
`321 NORTH CLARK STREET
`SUITE 2800
`CHICAGO, IL 60610-4764 (US)
`
`(21) Appl. No.:
`
`11/104,363
`
`(22) Filed:
`
`Apr. 12, 2005
`
`Related U.S. Application Data
`
`(60) Provisional application No. 60/562,157, filed on Apr.
`14, 2004.
`
`Publication Classification
`
`(51) Int. C1.7
`
`HO1M 2/02; HO1M 2/12;
`HO1M 2/08; HO1M 2/04
`
`(57)
`
`ABSTRACT
`
`An improved housing for a rolled-ribbon electrochemical
`device is provided. The housing comprises a fastener that
`aligns first and second cups during assembly and maintains
`electrode contact independent of external pressure on the
`housing eliminating the possibility of an open circuit state
`for a cell. In one alternative embodiment, the fastener
`comprises a stem that fits into a hollow tube and resists
`detachment from the tube. In another alternative embodi-
`ment, the fastener comprises a stem that fits into a grommet
`and resists detachment from the grommet. In yet another
`alternative embodiment, the fastener comprises a tube that
`fits into a grommet and resists detachment from the grom-
`met.
`
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`Eve Energy Co., Ltd v. Varta Microbattery Gmbh
`
`Eve Ex. 1029, p. 1
`
`

`

`Patent Application Publication Oct. 20, 2005 Sheet 1 of 10
`
`US 2005/0233212 Al
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`Eve Energy Co., Ltd v. Varta Microbattery Gmbh
`
`Eve Ex. 1029, p. 2
`
`

`

`Patent Application Publication Oct. 20, 2005 Sheet 2 of 10
`
`US 2005/0233212 Al
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`Eve Energy Co., Ltd v. Varta Microbattery Gmbh
`
`Eve Ex. 1029, p. 3
`
`

`

`Patent Application Publication Oct. 20, 2005 Sheet 3 of 10
`
`US 2005/0233212 Al
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`Eve Energy Co., Ltd v. Varta Microbattery Gmbh
`
`Eve Ex. 1029, p. 4
`
`

`

`Patent Application Publication Oct. 20, 2005 Sheet 4 of 10
`
`US 2005/0233212 Al
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`Eve Energy Co., Ltd v. Varta Microbattery Gmbh
`
`Eve Ex. 1029, p. 5
`
`

`

`Patent Application Publication Oct. 20, 2005 Sheet 5 of 10
`
`US 2005/0233212 Al
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`Eve Energy Co., Ltd v. Varta Microbattery Gmbh
`
`Eve Ex. 1029, p. 6
`
`

`

`Patent Application Publication Oct. 20, 2005 Sheet 6 of 10
`
`US 2005/0233212 Al
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`Eve Energy Co., Ltd v. Varta Microbattery Gmbh
`
`Eve Ex. 1029, p. 7
`
`

`

`Patent Application Publication Oct. 20, 2005 Sheet 7 of 10
`
`US 2005/0233212 Al
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`Eve Energy Co., Ltd v. Varta Microbattery Gmbh
`
`Eve Ex. 1029, p. 8
`
`

`

`Patent Application Publication Oct. 20, 2005 Sheet 8 of 10
`
`US 2005/0233212 Al
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`Eve Energy Co., Ltd v. Varta Microbattery Gmbh
`
`Eve Ex. 1029, p. 9
`
`

`

`Patent Application Publication Oct. 20, 2005 Sheet 9 of 10
`
`US 2005/0233212 Al
`
`Current(A), Voltage(V) vs. Test Time(s)
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`Eve Energy Co., Ltd v. Varta Microbattery Gmbh
`
`Eve Ex. 1029, p. 10
`
`

`

`Patent Application Publication Oct. 20, 2005 Sheet 10 of 10
`
`US 2005/0233212 Al
`
`Current(A), Voltage(V) vs. Test_Time(s)
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`Eve Energy Co., Ltd v. Varta Microbattery Gmbh
`
`Eve Ex. 1029, p. 11
`
`

`

`US 2005/0233212 Al
`
`Oct. 20, 2005
`
`1
`
`HOUSING FOR ELECTROCHEMICAL DEVICES
`
`CROSS-REFERENCE TO RELATED PATENT
`APPLICATIONS
`
`[0001] This application is an application claiming the
`benefit under 35 USC 119(e) U.S. Application 60/562,157,
`filed Apr. 14, 2004, incorporated herein by reference in its
`entirety.
`
`[0002] This invention was made with government support
`under Contract No. DMI-0349621 awarded to the National
`Science Foundation. The Government has certain rights in
`this invention.
`
`FIELD OF THE INVENTION
`
`[0003] The present invention relates to improved electro-
`chemical devices, such as batteries, capacitors, fuel cells,
`sensors or the like. More specifically this invention relates to
`improved housings for electrochemical devices that provide
`high specific power and energy outputs per weight and
`volume of the device.
`
`BACKGROUND OF THE INVENTION
`
`[0004] With the increasing pace of advances in electronics
`there has been a corresponding increase in the need for
`electrochemical devices that safely and efficiently provide
`sufficient energy density to power advanced electronic
`devices, especially portable electronic devices, while still
`being economically viable. Older battery configurations are
`often unsuitable to meet these increased demands. Out of
`environmental and efficiency concerns, the reach of elec-
`tricity providing devices has been expanded to new areas
`including hybrid electric vehicles. Ideally, an electrochemi-
`cal device will provide high current density, decrease the
`internal resistance of the battery, and effectively manage the
`thermal output of the electrochemical device to increase the
`longevity of the device. These features can be achieved by
`providing massive and/or large surface-area connections
`between electrodes and cell current collectors, and specifi-
`cally between cells in a battery.
`
`[0005] A second important feature of the high power
`device is internal heat removal. Thermal management is
`important to the long life of Li-ion batteries in retaining
`battery capacity particularly due to electrolyte degradation.
`High power to external circuitry generally generates a like
`amount of energy as heat over a short time duration and
`internal to the cell. Excessive temperatures will destroy (e.g.
`melt the microporous polymer separator or autoignite the
`flammable organic electrolyte) or significantly shorten the
`useful life of the Li-ion cell. Under high pulse power, heat
`is generated at the electrode/separator interface due to
`limited ionic conduction. For the conventional jelly-rolled
`cell, the most direct path for heat loss is across the layers of
`heat sensitive microporous polymer. Excessive temperature
`within the cell will locally shutdown the microporous poly-
`mer resulting in still higher temperatures possibly leading to
`the auto-ignition of the organic electrolyte.
`
`[0006] An electrochemical device comprised of cathode
`and anode electrodes physically exposed to an electrolyte
`can generically be used to convert between chemical and
`electrical energies. A housing can enclose these electrode
`and electrolyte components, and can even seal them from the
`
`atmosphere. Batteries, fuel cells, and capacitors are but a
`few such specific electrochemical devices to which this
`invention relates.
`
`[0007] As the electrical power in terms of voltage and/or
`amperage of each pair of cathode and anode electrodes (or
`cell) is generally small, many separate pairs of cathode and
`anode electrodes or cells can be used in a single housing.
`Current collectors are generally used to electrically inter-
`connect the cells, in parallel and/or in series, to provide
`usable voltage and amperage outputs at exposed terminals
`on the electrochemical device.
`
`[0008] The electrochemical device performs usable work
`when ions pass between the electrodes of each cell via the
`electrolyte, and when electrons concurrently pass through
`each cell via the electrodes. The generated voltage per cell
`is predetermined by the electrochemical reaction of the
`component materials used, and the generated amperage
`and/or power available is dependent on the configurations
`and masses of these active components.
`
`[0009] The specific output energy of the device can be
`provided in terms of watts-hours per device weight, and the
`specific output power of the device can be provided in terms
`of watts per device weight. Output values of existing elec-
`trochemical devices are typically small fractions of theo-
`retically possible output values because of internal resis-
`tances and other inefficiencies (hardware mass and volume).
`
`[0010] The resistance to ion conduction between the elec-
`trode elements is one major source for internal power loss.
`Such resistance, R, can be theoretically determined with the
`expression
`
`R=p1/A.
`[0011] where:
`
`[0012] "p" (rho) is the impedance value of the elec-
`trolyte;
`
`[0013] "1" is the thickness of the electrolyte; and
`
`[0014] "A" is the interfacial contact area between the
`electrode elements and electrolyte.
`
`[0015] The ionic-impedance value, p, is not easily subject
`to modification and is not effective as a design parameter.
`Designers of electrochemical devices thus strive to reduce
`the electrolyte thickness "I", and to increase the interfacial
`contact area "A" between the electrode elements and the
`electrolyte.
`
`[0016] Different configurations of the cathode and anode
`electrodes, of electrolyte separation, and of current collec-
`tion have been proposed. For example, a cathode electrode
`band can be zig-zagged to define separate compartments for
`holding the electrolyte, and inserted with elongated rod-like
`anode electrodes into the electrolyte spaced from the cath-
`ode electrode. The interfacial contact area "A" effectively is
`less than the overall surface area of the anode rods, as some
`rods oppose one another rather than the cathode.
`
`[0017] Also, a zig-zagged, folded separator band can
`define opposing compartments for holding and isolating
`plate-like cathode and anode electrodes, with electrolyte
`engulfing all of these components. In an alternative design,
`each cell can be formed with C-shaped electrodes and a
`Z-shaped separator sandwiched therebetween. Alternatively,
`
`Eve Energy Co., Ltd v. Varta Microbattery Gmbh
`
`Eve Ex. 1029, p. 12
`
`

`

`US 2005/0233212 Al
`
`Oct. 20, 2005
`
`2
`
`a separator band having electrically conductive surfaces can
`be folded and sandwiched between separate sets of respec-
`tive plate-like cathode and anode electrodes placed between
`the separate oppositely facing folds. A "jellyroll" cell can be
`formed by coiling a preformed assembly of cathode and
`anode electrodes and a separator on itself to yield a cylin-
`drically shaped electrochemical device, wherein the face-
`to-face electrodes and sandwiched electrolyte and separator
`structures increase the interfacial contact area "A" between
`the electrodes. However, the very breadth of the facing
`electrodes and sandwiched electrolyte and separator raise
`another issue, namely the sufficiency of the structure in
`maintaining and in supporting the electrode elements physi-
`cally separate during assembly and during operation. This
`includes withstanding thermal expansion and contraction
`forces of the cell components during operational tempera-
`ture changes. Increasing the thickness of the sandwiched
`electrolyte and separator to provide needed strength and/or
`durability also increases the ion-conducting electrolyte
`thickness "I", offsetting benefits obtained by increased inter-
`facial contact area "A".
`
`[0018] Current collectors used in these cell arrangements
`add significant weight, and thus reduced specific cell energy
`and power outputs. For example, isolated conductors are
`generally connected to the electrodes and routed along
`extended paths independently of the electrodes to the exter-
`nal terminals. These conductors should carry the full cell
`current, and thus should be of sufficient mass and cross-
`section to keep internal resistance manageably low. For a
`typical battery design of connected terminals, electrode
`tab/current collector/cell terminal resistance/battery termi-
`nal resistance can account for a 50% reduction in battery
`power output from theoretical capability. Generally, massive
`connectors are used to avoid power loss for high powered
`batteries.
`
`[0019] Additionally, these cell arrangements provide elec-
`trodes of limited size and/or thickness, limiting the quanti-
`ties of usable electrode materials, and thus, limiting maxi-
`mum cell storage energy and/or operating cycle-life,
`particularly for rechargeable cells.
`
`[0020] The dilemma of these designs is that power gains
`obtained by increasing the interfacial electrode area "A"
`across the electrolyte generally are typically offset by
`increased electrolyte thickness "I" and that the weight and
`volume of the current collectors reduce specific energy and
`power outputs. Power can be increased, but only at the
`expense of reduced energy storage capacity per weight and
`volume and at increased cost due to needed additional
`hardware. High interfacial area "A" of the spirally wound
`"jellyroll" configuration merely trades off usable power
`against the energy density because a minimum separator
`thickness is needed for cell durability and cycle-life. Exist-
`ing bipolar cell arrangements do not escape this power and
`energy trade off dilemma; nor do fuel cell electrochemical
`devices.
`
`[0021] The rolled-ribbon cell technology disclosed in U.S.
`Pat. No. 5,219,673 has made great strides towards achieving
`enhanced power density for electrochemical devices. Spe-
`cifically applied to Li/organic-based electrolyte chemistries,
`improved batteries are formed using stackable disk-shaped
`cells to realize near optimum power capability from the
`cells. Further objectives of batteries for high-pulse power
`
`requirements, such as for hybrid electric vehicles and for
`power tools, are to continue to reduce battery cost and to
`increase durability. These Li/organic-based electrolyte bat-
`tery chemistries, although exhibiting quite high voltages
`(3-5 volts), have relatively low current density capabilities.
`One limiting factor is the attempted use of relatively-thin
`components, i.e. the electrode and separator layers. A prac-
`tical device generally, requires a lot of active area. For
`example, with peak current density of 10 mA/cm2' it can
`require 1000 cm2 active area to achieve 10 A. For hybrid
`electric vehicles, the current is on the order of 100 A at
`200-400 volts (equivalent to 20-40 kW).
`
`[0022] Thus, a further dilemma is the large number of
`small cells that form such batteries. Internal heat generation
`resulting from the large numbers of small cells (e.g. 1
`Ampere-hour (Ah) capacity uses 18,650 cells) is a major
`power loss source. More recently, larger cells (10 Ah) have
`used a prismatic configuration. These cells have broad
`electrodes with multiple tabs connected to a traditional
`terminal connection. These prismatic cells are hard-wired
`together (terminal-to-terminal) in a rectangular box. None-
`theless, this arrangement of substantially larger cells can still
`sacrifice 50% of the theoretical power of the cell chemistry.
`Thus, there is a continuing and persistent need for electro-
`chemical devices which have high energy density, provide
`high power output, and approach the theoretical limit for
`electrical power output.
`
`[0023] A Li/organic-based electrolyte battery for high
`power applications, such as for hybrid electric vehicles,
`should also incorporate features to enhance safety and
`battery longevity. Because there is internal gas pressure
`generated during battery operation and during battery deg-
`radation conditions, there needs to be non-catastrophic, cost
`effective means to relieve the gas pressure. The typical
`means is to include a rupture disc on the housing of the
`Li-ion cell. Rupture of a disc housing causes irreversible
`failure of that battery, and, if a disc ruptures, electrolyte may
`escape to further degrade the battery. Additionally, because
`the electrolyte batteries often operate in environments that
`cause both shock to and vibration of the battery, the battery
`should be durable.
`
`SUMMARY OF THE INVENTION
`[0024] An embodiment of the present invention provides
`a housing for an electrochemical device comprising a first
`cup, a second cup, a fastener, and a gasket. The first cup may
`include a first plate having a circumferential edge and a first
`wall, the first wall extending from the first plate along the
`circumferential edge. The second cup may include a second
`plate having a circumferential edge and a second wall, the
`second wall extending from the second plate along the
`circumferential edge, wherein the first cup fits together with
`the second cup thereby creating an enclosure. The fastener
`may include a threaded stem made of conducting material
`and extending from the center of the first plate in the same
`general direction as the first wall and a hollow tube made of
`insulating material and extending from the center of the
`second plate in the same general direction as the second
`wall, wherein the threaded stem fits inside the hollow tube
`and assists in holding the second cup together with the first
`cup. The gasket may be made of plastic material that fits
`over the first wall wherein the gasket electrically isolates the
`first cup from the second cup and seals the enclosure from
`the ambient atmosphere surrounding the housing.
`
`Eve Energy Co., Ltd v. Varta Microbattery Gmbh
`
`Eve Ex. 1029, p. 13
`
`

`

`US 2005/0233212 Al
`
`Oct. 20, 2005
`
`3
`
`[0025] Certain embodiments of the present invention are
`found in the following paragraphs:
`
`[0026] A housing for an electrochemical device compris-
`ing:
`
`[0027] (a) a first cup, the first cup comprising
`
`[0028] (1) a first plate having a circumferential edge;
`and
`
`[0029] (2) a first wall, the first wall extending from
`the first plate along the circumferential edge;
`
`[0030] (b) a second cup, the second cup comprising
`
`[0031] (1) a second plate having a circumferential
`edge; and
`
`[0032] (2) a second wall, the second wall extending
`from the second plate along the circumferential edge,
`wherein the first cup and the second cup are capable
`of fitting together thereby creating an enclosure; and
`
`[0049] The housing of any one of paragraphs [0027] to
`[0031] wherein the tube is hollow and includes a side
`channel to an interior of the electrochemical device, thereby
`allowing gases to escape.
`
`[0050] The housing of paragraph [0030], wherein one or
`more of the tube and the grommet is threaded.
`
`[0051] The housing of any one of paragraphs [0020] to
`[0033], further comprising a gasket wherein the gasket
`electrically isolates the upper cup from the lower cup.
`
`[0052] The housing of paragraph [0034], wherein the
`gasket comprises a plastic material.
`
`[0053] The housing of paragraph [0034] or [0035],
`wherein the gasket fits over one or more of the wall of the
`first cup and the wall of the second cup.
`
`[0054] The housing of any one of paragraphs [0020] to
`[0036] wherein the first cup and the second cup comprise the
`same material.
`
`[0033] (c) a fastener, wherein the fastener attaches
`the first cup to the second cup.
`
`[0055] The housing of any one of paragraphs [0020] to
`[0037], further comprising:
`
`[0034] The housing of paragraph [0020], wherein the
`fastener comprises:
`
`[0035] (a) one or more stems; and
`
`[0036] (b) one or more tubes, wherein the one or
`more stems fit inside one or more of the one or more
`tubes.
`
`[0037] The housing of paragraph [0021], wherein one or
`more of the one or more tubes and the one or more stems at
`least partially comprises an insulating material.
`
`[0038] The housing of paragraph [0022], wherein the
`insulating material comprises a plastic material.
`
`[0039] The housing of any one of paragraphs [0021] to
`[0023], wherein one or more of the one or more tubes and
`the one or more stems at least partially comprises a con-
`ducting material.
`
`[0040] The housing of claim paragraph [0024], wherein
`the conducting material comprises a metal.
`
`[0041] The housing of any one of paragraphs [0021] to
`[0025], wherein one or more of the one or more stems and
`the one or more tubes is threaded.
`
`[0042] The housing of any one of paragraphs [0020] to
`[0026], wherein the fastener comprises:
`
`[0043] (a) a grommet; and
`
`[0044] (b) a tube, wherein the tube fits inside the
`grommet and is attached thereto.
`
`[0045] The housing of paragraph [0027], wherein one or
`more of the grommet and the tube is at least partially
`comprised of an insulating material.
`
`[0046] The housing of paragraph [0028], wherein the
`insulating material comprises a plastic material.
`
`[0047] The housing of any one of paragraphs [0027] to
`[0029], wherein one or more of the grommet and the tube is
`at least partially comprised of a conducting material.
`
`[0048] The housing of paragraph [0030], wherein the
`conducting material comprises a metal.
`
`[0056] (a) an electrode assembly comprising:
`
`[0057] (i) a positive electrode layer wherein the posi-
`tive electrode layer is electrically coupled to one of
`the first cup and the second cup;
`
`[0058] (ii) a negative electrode layer wherein the
`negative electrode layer is electrically coupled to the
`other of the first cup or the second cup; and
`
`[0059] (iii) a separation layer, wherein the positive
`electrode layer, the separation layer, and the negative
`electrode layer are wound around a central axis
`forming a coil of alternating electrode and separation
`layers such that the separation layer prevents direct
`contact between the positive electrode layer and the
`negative electrode layer; and
`
`[0060] (b) an electrolyte adjacent to the electrode
`assembly and enclosed within the enclosure.
`
`[0061] Other principal features and advantages of the
`invention will become apparent to those skilled in the art
`upon review of the following drawings, the detailed descrip-
`tion, and the appended claims.
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`[0062] The exemplary embodiments will hereafter be
`described with reference to the accompanying drawings,
`wherein like numerals will denote like elements.
`
`[0063] FIG. 1 is a cut-away perspective view of the
`electrode/separation layer configuration in the electrode
`assembly in accordance with an exemplary embodiment.
`
`[0064] FIG. 2 is a right side facial view showing the
`electrode assembly of FIG. 1 coiled on itself to define a
`rolled-ribbon cell (laminate cell membrane) of the type
`suited for forming an electrochemical device in accordance
`with an exemplary embodiment.
`
`[0065] FIG. 3 depicts the process for making the elec-
`trode/separator assembly in accordance with an exemplary
`embodiment.
`
`Eve Energy Co., Ltd v. Varta Microbattery Gmbh
`
`Eve Ex. 1029, p. 14
`
`

`

`US 2005/0233212 Al
`
`Oct. 20, 2005
`
`4
`
`[0066] FIG. 4 is a cross-sectional view of the cell preas-
`sembly taken along line 4-4 of the process of FIG. 3.
`
`[0067] FIG. 5 is a cross-sectional view of the cell preas-
`sembly taken along line 5-5 of the process of FIG. 3.
`
`[0068] FIG. 6 is a cross-sectional view of the cell preas-
`sembly taken along line 6-6 of the process of FIG. 3.
`
`[0069] FIG. 7A depicts the housing for the electrochemi-
`cal device in accordance with an exemplary embodiment;
`FIG. 7B depicts a cross-sectional view of the peripheral seal
`area of the housing for the electrochemical device including
`the `I_J' shaped polymeric gasket; FIG. 7C depicts the outer
`pan of the housing for the electrochemical device including
`the center fastener, polymeric tube; FIG. 7D depicts a
`cross-sectional view of the housing for the electrochemical
`device including the `I_J' shaped polymeric gasket and the
`threaded stem and plastic tube fastener.
`
`[0070] FIG. 8 depicts a radial view of the housing for the
`electrochemical device including a fastener in accordance
`with an exemplary embodiment.
`
`[0071] FIG. 9A depicts a radial view of the plastic tube
`portion of the fastener for the housing of the electrochemical
`device; FIG. 9B depicts a cross-sectional view of a washer
`for attaching the fastener in accordance with an exemplary
`embodiment; FIG. 9C depicts a cross sectional view of the
`plastic tube portion.
`
`[0072] FIG. 10A depicts a cross sectional view of the
`housing for the electrochemical device showing a fastener
`including a plastic tube and grommet; FIG. 10B depicts a
`cross sectional view of the housing for the electrochemical
`device showing a fastener including a plastic tube and
`grommet along with a detailed cross sectional view of the
`fastener and a cut away radial view of the housing with the
`fastener; FIG. 10C depicts a pictorial cross sectional view
`of the housing for the electrochemical device showing a
`fastener including a plastic tube and grommet along with a
`detailed cross sectional view of the fastener.
`
`[0073] FIG. 11 is a radial edge section of a bipolar
`electrochemical device incorporating the electrode assembly
`in accordance with an exemplary embodiment.
`
`[0074] FIG. 12A shows a high voltage battery made up by
`stacking disc-shaped electrochemical cells in accordance
`with an exemplary embodiment; FIG. 12B shows an end
`cross-sectional view; FIG. 12C shows a detailed cross-
`sectional view of the high voltage battery, taken along line
`12-12.
`
`[0075] FIG. 13A depicts an embodiment that can achieve
`greater cooling of the electrochemical cells; FIG. 13B
`shows a cross-sectional view of a battery housing with
`cooling jacket.
`
`[0076] FIG. 14 depicts a current vs. time profile and
`voltage vs. time profile for a cell under a compressive load.
`
`[0077] FIG. 15 depicts a current vs. time profile and
`voltage vs. time profile for a cell in accordance with an
`exemplary embodiment wherein the cell is not under a
`compressive load.
`
`DETAILED DESCRIPTION OF THE
`INVENTION
`[0078] Exemplary embodiments described herein provide
`an improved cell arrangement involving the orientation of
`
`positive and negative electrodes (as depicted in the drawings
`throughout and referred to as e.g. 28p, 22p, etc.), interpo-
`sitioned separator and/or electrolyte, and current collectors.
`The improved cell uses an electrode assembly with lami-
`nated electrode/foils comprised of alternately arranged, gen-
`erally parallel, positive and negative electrodes, and a sepa-
`rator layer and/or electrolyte formed of a very thin ionic-
`conductive ribbon-like layer configured in a tight serpentine
`manner and physically interposed between the electrodes.
`This basic laminate cell preassembly is layered on itself,
`such as by winding or coiling it in a spiral to form an
`electrode assembly in the general shape of a flat disc
`(wherein the diameter is preferably greater than twice the
`thickness of the disk). The cell membrane is sandwiched
`between plate-like current collectors with the electrode
`interfaces primarily perpendicular to the current collectors to
`make up an electrochemical cell.
`[0079] Because of the expense of lithium ion batteries,
`which also provide the greatest electrochemical potential
`and largest energy content, the rolled-ribbon cell configu-
`ration has particular utility for cells employing lithium/
`organic electrolyte cell chemistry, although the present
`invention is also well suited to other cell chemistries,
`including, but not limited to, nickel/metal hydride and
`alkaline electrolyte systems. Of particular interest, the tech-
`nology provides high pulse power devices at reduced costs
`and with excellent thermal management producing kW
`levels of power.
`[0080] The improved cell arrangement in an exemplary
`embodiment uses a ribbon-like cell assembly with coated
`foil electrode strips extending beyond the edge of the folded
`separator when viewed in cross section. The extended elec-
`trode areas can have less or no active electrode material, and
`the electrode ribbons are preferably cored with metal foils or
`other electron conducting material e.g. carbon paper and/or
`electrically conductive polymer. For a 5 inch diameter cell,
`100 to 250 ft of electrode edge contact with a cell housing
`is typically achieved.
`[0081] The exemplary embodiments provide for adding
`electrode material or cell capacity by way of extending the
`electrode strips beyond the separation layer. Instead of
`having electrode discs applied to the major faces of the
`rolled-ribbon cell or cell separator membrane, as in earlier
`button type electrochemical cells, the electrode extensions
`define reservoirs of electrode material. These extensions are
`subsequently compacted into a disc as the cell is assembled
`into the disc housing hardware.
`[0082] The exemplary embodiments also provide for a
`separator ribbon configuration in which the folds of the
`separation layer are oriented up and down at each edge. This
`arrangement serves to align the electrode ribbons with
`respect to the separator and helps to ensure the positioning
`of the electrodes and separator during the cell winding
`operation. This alignment aids in forming a flat disc cell.
`[0083] The exemplary embodiments can provide an elec-
`tronic component that can serve to electrically remove a
`shorted or defective cell. Preferably the electronic compo-
`nent is embedded within the cell and resides at the center
`hub of the cell for ease of manufacture, for example by
`initiating the cell winding. In a preferred embodiment, a
`diode is utilized for removing (or short-circuiting) the non-
`operative cell. Similarly, the component can act to bypass
`current at overcharge or excessive voltage conditions.
`
`Eve Energy Co., Ltd v. Varta Microbattery Gmbh
`
`Eve Ex. 1029, p. 15
`
`

`

`US 2005/0233212 Al
`
`Oct. 20, 2005
`
`5
`
`[0084] The invention also provides a button-type cell
`housing. The housing comprises two opposing shallow cups,
`a first cup and a second cup, that are electrically isolated
`from each other using a polymeric "U" shaped gasket. Each
`cup comprises an essentially flat surface surrounded by a
`wall that extends from the flat surface or plate creating a
`receptacle or enclosur