Battery configuration with corrosion barrier

Abstract

The present invention is entitled "Battery Configuration with Corrosion Barrier". A rechargeable battery cell according to an embodiment of the present technology may include a housing having a first conductive segment operable at an anode potential. The housing may include a second conductive segment operable at a cathode potential. The housing may include a gasket positioned between the first conductive segment and the second conductive segment and configured to hermetically seal the housing. The unit may include an electrode stack containing an anode. The anode may include an anode tab electrically coupled to the first conductive segment of the housing. The electrode stack may include a cathode. The cathode may include a cathode tab electrically coupled to the second conductive segment of the housing. The unit may include a barrier material disposed between the cathode tab and the second conductive segment of the housing. The cathode tab may be electrically coupled to the second conductive segment of the housing through the barrier material.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of U.S. Provisional 63 / 176,475, filed on April 19, 2021, entitled “Battery Configurations with Corrosion Barrier,” the disclosure of which is hereby incorporated by reference in its entirety. Technical Field

[0003] The present technology relates to batteries. More specifically, the present technology relates to battery component configurations. Background Art

[0004] Batteries are used in many devices. As increased energy density is sought in reduced form factors, device configuration and coupling can present challenges. Summary of the invention

[0005] A rechargeable battery cell according to some embodiments of the present technology may include a housing having a first conductive segment operable at an anode potential. The housing may include a second conductive segment operable at a cathode potential. The housing may include a gasket positioned between the first conductive segment and the second conductive segment and configured to hermetically seal the housing. The unit may include an electrode stack containing an anode. The anode may include an anode tab electrically coupled to the first conductive segment of the housing. The electrode stack may include a cathode. The cathode may include a cathode tab electrically coupled to the second conductive segment of the housing. The unit may include a barrier material at least partially disposed between the cathode tab and the second conductive segment of the housing. The cathode tab may be electrically coupled to the second conductive segment of the housing through the barrier material.

[0006] In some embodiments, the second conductive segment can be stainless steel. The barrier material can be characterized by an annular shape. The cathode tab can be coupled to the second conductive segment of the housing at an orifice defining an inner annular radius of the annular shape of the barrier material. The orifice can be characterized by an elliptical or rectangular shape. The cathode tab can be characterized by a first surface coupled to the second conductive segment of the housing and a second surface opposite to the first surface. The rechargeable battery cell may include a first insulating material that contacts the first surface of the cathode tab and extends partially along the first surface of the cathode tab. The first insulating material may be positioned adjacent to the barrier material. The unit may include a second insulating material that contacts the second surface of the cathode tab and extends partially along the second surface of the cathode tab. The second insulating material may extend beyond the lateral edge of the cathode tab, and the second insulating material may contact the barrier material outside the cathode tab. The second insulating material may cover the orifice defining the inner annular radius of the barrier material. The second insulating material may be characterized by an end region shaped to cover the aperture defining the inner annular radius of the barrier material. The barrier material, the first insulating material and the second insulating material may each comprise a similar material. The similar material may be a viscous polymer material.

[0007] Some embodiments of the present technology may include a rechargeable battery cell. The cell may include a button cell housing. The housing may include a first conductive segment, a second conductive segment, and a gasket positioned between the first conductive segment and the second conductive segment and configured to seal the button cell housing. The battery may include an electrode stack including an anode and a cathode. The cathode may include a cathode tab that is physically and electrically coupled to the second conductive segment of the housing. The cell may include a barrier material that is at least partially disposed between the cathode tab and the second conductive segment of the button cell housing. The cathode tab may extend through the barrier material and be physically and electrically coupled to the second conductive segment of the housing.

[0008] In some embodiments, the barrier material may be a material comprising a sticky surface. The sticky surface may extend in contact with the second conductive segment of the button cell housing. The barrier material may be characterized by an annular shape. The cathode tab may be coupled to the second conductive segment of the housing at an orifice defining an inner annular radius of the annular shape of the barrier material. The cathode tab may be characterized by a first surface coupled to the second conductive segment of the housing and a second surface opposite to the first surface. The rechargeable battery cell may include a first insulating material that contacts the first surface of the cathode tab and extends partially along the first surface of the cathode tab. The first insulating material may be a material comprising a sticky surface. The sticky surface may extend in contact with the cathode tab. The surface of the first insulating material opposite to the sticky surface may extend in contact with the barrier material. The cell may include a second insulating material that contacts the second surface of the cathode tab and extends partially along the second surface of the cathode tab. The second insulating material may be a material comprising a sticky surface. The adhesive surface may extend in contact with the cathode tab. An edge region of the adhesive surface may contact the barrier material.

[0009] Some embodiments of the present technology may include a rechargeable battery cell. The cell may include a housing including: a first conductive segment operable at an anode potential; a second conductive segment operable at a cathode potential; and a gasket positioned between the first conductive segment and the second conductive segment and configured to hermetically seal the housing. The cell may include an electrode stack containing an anode. The anode may include an anode tab electrically coupled to the first conductive segment of the housing. The electrode stack may include a cathode, which may include a cathode tab electrically coupled to the second conductive segment of the housing. The cathode tab may be characterized by a first surface coupled to the second conductive segment of the housing and a second surface opposite to the first surface. The cell may include a barrier material that contains the cathode tab and is disposed between the electrode stack and the second conductive segment of the housing. The cathode tab may be electrically coupled to the second conductive segment of the housing through the barrier material.

[0010] Such technology can provide many benefits over conventional technology. For example, the battery of the present invention can reduce corrosion of conductive housing components. In addition, the battery can facilitate electrode connection within the battery housing incorporating barrier materials. These and other embodiments, as well as many of their advantages and features, are described in more detail in conjunction with the following description and accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] A further understanding of the nature and advantages of the disclosed embodiments may be realized by reference to the remainder of the specification and drawings.

[0012] Figure 1 Schematic cross-sectional views of battery cell materials according to some embodiments of the present technology are shown.

[0013] Figure 2 A schematic front cross-sectional view of a battery according to some embodiments of the present technology is shown.

[0014] Figure 3A Schematic diagrams of battery materials according to some embodiments of the present technology are shown.

[0015] Figure 3B Schematic diagrams of battery materials according to some embodiments of the present technology are shown.

[0016] Figure 3C Schematic diagrams of battery materials according to some embodiments of the present technology are shown.

[0017] Figure 4 A schematic front cross-sectional view of a battery material according to some embodiments of the present technology is shown.

[0018] Figure 5 Schematic diagrams of battery materials according to some embodiments of the present technology are shown.

[0019] Figure 6 Schematic diagrams of insulating materials according to some embodiments of the present technology are shown.

[0020] Figure 7 Schematic diagrams of insulating materials according to some embodiments of the present technology are shown.

[0021] Figure 8 A schematic front cross-sectional view of a battery material according to some embodiments of the present technology is shown.

[0022] Several of these drawings are included as schematic diagrams. It should be understood that the drawings are for illustrative purposes only and should not be considered to scale or proportion unless specifically indicated to scale or proportion. Additionally, as schematic diagrams, the drawings are provided to aid understanding and may not include all aspects or information as compared to actual representation and may include exaggerated material for illustrative purposes.

[0023] In the accompanying drawings, similar components or features may have the same numerical reference numerals. In addition, various components of the same type may be distinguished by using a letter after the reference numeral to distinguish between similar components and / or features. If only the first numerical reference numeral is used in the specification, the description applies to any one of the similar components and / or features having the same first numerical reference numeral, regardless of the letter suffix. DETAILED DESCRIPTION

[0024] Batteries, battery cells, and more generally energy storage devices are used in a host of different systems. In many devices, battery cells may be designed with a balance of characteristics in mind. For example, including a larger battery may provide increased use between charges, however, a larger battery may require a larger housing, or increase space within the device. As device designs and configurations change, particularly in terms of reducing device size, the available space for additional battery components may be constrained. These constraints may include limitations on the available volume and the geometry of such volume.

[0025] Button cells may typically be primary cells or non-rechargeable cells. Primary cells may allow for increased electrode thickness because a reverse electrochemical process cannot be performed. For lithium-ion or other rechargeable battery designs, there may be challenges that make conventional techniques unsuitable for rechargeable designs. For example, button cells typically include a conductive housing that operates at an anode potential and a cathode potential. Some materials may include stainless steel, among many others. The electrolyte of a lithium-ion battery may include materials that can promote corrosion reactions of stainless steel. This corrosion may be exacerbated when there is a visual path between the cell electrodes and the housing. Therefore, many conventional techniques avoid these materials, or accept a reduced service life due to the effects of corrosion.

[0026] However, the present technology can overcome these problems by providing a configuration that limits or prevents any direct visual access between the electrode stack of the battery cell and the housing operating at the cathode potential. By incorporating additional barrier material along the cathode housing and which accommodates the cathode tab, corrosion within the battery cell can be reduced or eliminated. After illustrating an exemplary cell that can be used in embodiments of the present technology, the present disclosure will describe battery designs having components and configurations for use in various devices in which the battery cell can be used.

[0027] Although the remainder of the specification will refer to lithium-ion batteries, those skilled in the art will readily appreciate that the technology is not limited thereto. The technology can be used with any number of batteries or energy storage devices, including other rechargeable battery types and primary battery types, as well as secondary batteries or electrochemical capacitors. In addition, the technology can be applicable to batteries and energy storage devices used in any number of technologies, which may include but are not limited to phones and mobile devices, watches, glasses, bracelets, anklets and other wearable technologies, including fitness equipment, handheld electronic devices, laptops and other computers, motor vehicles and other transportation equipment, and other devices that may benefit from the use of the various described battery technologies.

[0028] Figure 1A schematic cross-sectional view of materials of an energy storage device or battery cell 100 according to an embodiment of the present technology is shown. The battery cell 100 may be or include an electrode stack, and may be one of a plurality of stacks coupled together to form a battery structure. As will be readily appreciated, these layers are not shown to any particular scale, and are intended only to illustrate possible cell material layers that may be incorporated into one or more cells in an energy storage device. In some embodiments, such as Figure 1 As shown, the battery cell 100 includes a first current collector 105 and a second current collector 110. In an embodiment, one or both current collectors may include a metal or non-metallic material, such as a polymer or a composite that may include a conductive material. The first current collector 105 and the second current collector 110 may be different materials in the embodiment. For example, in some embodiments, the first current collector 105 may be a material selected based on the potential of the anode active material 115, and may be or include copper, stainless steel, or any other suitable metal and a non-metallic material including a polymer. The second current collector 110 may be a material selected based on the potential of the cathode active material 120, and may be or include aluminum, stainless steel, or other suitable metal and a non-metallic material including a polymer. In other words, the materials for the first current collector and the second current collector may be selected based on the electrochemical compatibility with the anode active material and the cathode active material used, and may be any material known to be compatible.

[0029] In some cases, the metal or non-metal used for the first current collector and the second current collector may be the same or different. The material selected for the anode active material and the cathode active material may be any suitable battery material that can be operated in a rechargeable battery design as well as a primary battery design. For example, the anode active material 115 may be silicon, graphite, carbon, a tin alloy, lithium metal, a lithium-containing material such as lithium titanium oxide, or other suitable materials that can form an anode in a battery cell. In addition, for example, the cathode active material 120 may be a lithium-containing material. In some embodiments, the lithium-containing material may be a lithium metal oxide such as lithium cobalt oxide, lithium manganese oxide, lithium nickel manganese cobalt oxide, lithium nickel cobalt aluminum oxide, or lithium titanate, while in other embodiments, the lithium-containing material may be lithium iron phosphate or other suitable materials that can form a cathode in a battery cell.

[0030] The first current collector and the second current collector and the active material may have any suitable thickness. The separator 125 may be disposed between the electrodes and may be a polymer film or a material that allows lithium ions to pass through the structure rather than otherwise conduct electricity. In a complete unit configuration, the active materials 115 and 120 may also include an amount of electrolyte, which may also be absorbed in the separator 125. The electrolyte may be a liquid containing one or more salt compounds dissolved in one or more solvents. In an embodiment, the salt compound may include a lithium salt compound, and may include one or more lithium salts, including, for example, lithium compounds doped with one or more halogen elements such as fluorine or chlorine, and other non-metallic elements such as phosphorus and semi-metallic elements including, for example, boron.

[0031] In some embodiments, the salt may include any lithium-containing material that is soluble in an organic solvent. The solvent included with the lithium-containing salt may be an organic solvent and may include one or more carbonates. For example, the solvent may include one or more carbonates, including propylene carbonate, ethylene carbonate, ethyl methyl carbonate, dimethyl carbonate, diethyl carbonate, and fluoroethylene carbonate. Combinations of solvents may be included, and may include, for example, propylene carbonate and ethyl methyl carbonate as an exemplary combination. Any other solvent may be included that enables dissolution of one or more lithium-containing salts and other electrolyte components, or that may provide useful ionic conductivity, such as greater than or about 5 -10 mS / cm.

[0032] Although shown as a single-layer electrode material, the battery cell 100 can be any number of layers. Although the unit can be composed of anode material and cathode material as a layer of sheet material, these layers can also be formed so that any number of layers can be included in any form in the battery cell 100. For embodiments including multiple layers, the tab portion of each anode current collector can be coupled together, such as the tab portion of each cathode current collector, although one or more current collectors can be continuous current collector materials, as described below. Once the unit has been formed, a bag-shaped portion, a shell or a shell can be formed around the unit to contain electrolytes and other materials in the unit structure. The terminal can extend from the shell to allow the electrical coupling of the unit for the device, including the anode terminal and the cathode terminal. The coupling can be directly connected to the load that can utilize power, and in some embodiments, the battery cell can be coupled to a control module that can monitor and control the charging and discharging of the battery cell. When multiple batteries are stacked together, the electrode terminals in the anode potential can be coupled together, such as the electrode terminals in the cathode potential. These coupled terminals can then be connected to the terminals on the shell as described above.

[0033] The structure of the battery cell 100 may also illustrate the structure of a solid-state battery cell, which may include anode materials and cathode materials and a current collector as described above. The difference between the solid-state design and the previously described liquid-electrolyte design is that, in addition to not including an electrolyte, the separator 125 may be characterized by different materials, although the material may be characterized by similar properties (such as the ability to allow ions to pass through the material while limiting the passage of electrons). In the solid-state configuration, the anode material and the cathode material may be any of the above materials, as well as additional materials that can be operated as electrode active materials within the solid-state cell. For example, the anode material may include graphene or carbon materials, lithium metal, titanium-containing materials, lithium alloys, and other anode compatible materials. The cathode material may include lithium-containing oxides or phosphates, as well as other cathode compatible materials. The inter-electrode material, which may also be labeled as 125, may include an electron blocking material, such as a separator, and or alternatively, a solid electrolyte material with ion mobility. Glass materials and ceramics may be used, as well as polymer materials that may contain ion conductive additives such as lithium salts. In any instance where the word "separator" is used, it should be understood to encompass both the separator and the solid electrolyte, which may or may not be incorporated with the separator material. Figure 1 Included as exemplary cells that may be incorporated into batteries according to the present technology. However, it should be understood that any number of battery and battery cell designs and materials that may similarly include charge and discharge capabilities may be encompassed by or incorporated with the present technology.

[0034] Figure 2 A schematic front cross-sectional view of a battery cell 200 according to some embodiments of the present technology is shown. The battery cell 200 may illustrate a button cell battery housing, but it should be understood that the present technology similarly encompasses any number of other housing configurations, wherein the electrode stack as described throughout the present disclosure can accommodate configurations and geometries beyond the number of non-limiting examples shown. The battery cell 200 may include an electrode stack as previously described, which may include any of the components described above for the battery cell 100, including any number of cells or configurations and any other electrode stack materials. It should be understood that the drawings are not made to any particular scale for any component. For example, in some embodiments, the electrode stack may consume most of the internal volume, and the scale shown is not intended to limit or necessarily represent anything beyond the structural configuration of the battery cell according to some embodiments of the present technology.

[0035] The housing of the battery cell 200 may include a first conductive segment 205 that can be electrically coupled to the anode current collector (such as with an anode tab 207) and can be operated at an anode potential. In addition, the housing may include a second conductive segment 210 that can be electrically coupled to the cathode current collector (such as with a cathode tab 212) and can be operated at a cathode potential. It should be understood that in some embodiments, the structure can be reversed, such as by reversing the electrode stack, which can then switch the coupling and operating potential of the housing segments, which is similarly covered by the present technology. In some embodiments, a gasket 215 can be positioned between the first conductive segment and the second conductive segment and can facilitate the hermetic sealing of the housing and the battery cell. The gasket can be any number of components, such as a plastic or elastomeric o-ring, a glass or ceramic feedthrough, or any other mechanism that can couple the two housing segments and can also maintain electrical isolation between the two housing segments, and the two housing segments can operate at potentials opposite to each other. Although the housing segments are shown as simply overlapping the gasket, it should be understood that any number of couplings (including crimping, welding or other mechanical couplings) or any other type of coupling are similarly encompassed by the present technology. Therefore, multiple housing configurations for button cell battery cells and other styles of housings are similarly encompassed.

[0036] As shown, electrode stack 220 may be included in the housing, and it may include any number of anodes or cathodes as previously described. The electrode stack may be a plurality of stacked electrodes, or may be a winding design or folded configuration, and may be a roll core, layer or electrode material, prismatic battery stack or any other type of battery configuration that may be incorporated in the housing. As shown, the electrode tab may be coupled to each of the anode and cathode, and the tab may be coupled to the housing segment. As described above, the anode tab 207 may be coupled to the first conductive segment 205 of the housing, and the cathode tab 212 may be coupled to the second conductive segment 210 of the housing. In some embodiments, the coupling may be any physical coupling or electrical coupling, and may be a conductive tab that may be bonded, bonded, welded or otherwise physically coupled to the housing segment to provide electrical coupling with the associated housing segment.

[0037] In some embodiments, the first conductive segment 205 of the battery cell housing and the second conductive segment 210 of the battery cell housing can each be characterized by a flat base and a side wall, which can extend circumferentially around the flat base at least partially, and depending on the side wall profile, can extend at a certain angle and orthogonally to the flat base, which can define the volume of the battery cell. The flat base of each segment of the housing can extend at least partially parallel to each other, and can extend substantially parallel to each other and to the first and second segments of each of the anode current collector and the cathode current collector and to each intermediate planar segment as shown. The conductive segments can be formed of any metal, alloy or other conductive material (such as stainless steel or other housing materials). In addition, the outer surface can be a dielectric material or other material, including conductive contacts for electrically coupling the battery to the device.

[0038] As shown, due to coupling with the anode current collector, the first conductive segment 205 of the housing can be maintained at an anode potential, which can be a cathode potential in the reverse orientation of the electrode stack 220 in other embodiments. The sidewalls of the first conductive segment 205 may at least partially radially define the volume of the battery cell and may be exposed to the cathode current collector along one or more folds of the electrode stack. Although the electrode stack may be spaced apart to accommodate the gap, or the spacer may be positioned within the volume, this may reduce the volume occupied by the electrode stack and may reduce the energy density of the battery cell. Therefore, in some embodiments in which a roll core or other packaging configuration may be used, the outer layer of the electrode stack may be an anode material that may reduce or limit the possibility of an internal short circuit with the sidewall of the housing at the anode potential. Alternatively or in addition, the inner sidewalls of the first conductive segment 205 may be passivated or coated to limit electrical interaction with the electrode stack. In addition, the battery cell may include an electrolyte incorporated in the housing.

[0039] As described above, when stainless steel may be used as the housing segment, the second conductive segment 210 may operate at a cathode potential. Depending on the electrolyte material utilized within the cell, corrosion reactions may occur when the electrode stack is held in the housing without being physically separated from the housing segment. However, simply incorporating a spacer between the electrode stack and the second conductive segment 210 of the housing may make coupling the electrode to the housing segment challenging or obstructed. This problem may be partially attributed to the sidewalls of the second conductive segment extending radially outward from the sidewalls of the first conductive segment 205 and being at least partially blocked by the sidewalls of the first conductive segment, which may at least partially define the internal volume of the battery cell. Therefore, if the entire base of the second conductive housing segment 210 is covered by the spacer, electrical coupling may not be feasible. The present technology may overcome this situation by incorporating a barrier material that may allow electrode coupling while maintaining a physical barrier between the electrode stack and the housing segment at the cathode potential.

[0040] Figure 3A A schematic diagram of a battery material 300 according to some embodiments of the present technology is shown, which battery material may include a barrier material for reducing or limiting corrosion of a housing segment at a cathode potential. The battery material 300 may include a top plan view of the second conductive segment 210 of the housing, wherein the electrode stack and the first conductive segment are removed. Disposed on the base of the second conductive segment 210 may be a barrier material 310, which in some embodiments may be at least partially disposed between a cathode tab of the electrode stack (such as the cathode tab 212 described above) and the second conductive segment 210 of the housing. The barrier material 310 may be disposed between the electrode stack and the second conductive segment of the housing, however the cathode tab may at least partially extend through the barrier material or be coupled by the barrier material to electrically couple with the second conductive segment of the housing.

[0041] The barrier material 310 can be any number of coatings or materials that can be disposed on the inner surface of the base of the second conductive segment 210. As will be explained below, in some embodiments, the barrier material can be a complete coating through which welding can be performed, while in some embodiments, the barrier material 310 can define an aperture 312 through which the cathode tab can extend to physically couple and / or electrically couple with the second conductive segment 210. The barrier material 310 can be characterized by any shape or geometry, and can be characterized by a shape similar to the second conductive segment 210, the electrode stack to which it is attached, or both. For example, in some embodiments, the second conductive segment of the housing can be characterized by an elliptical shape (including a circular or other arcuate shape). The barrier material 310 can similarly be characterized by an outer radius that can be less than the inner radius of the second conductive segment 210, and can be a size less than the inner radius of the sidewall of the first conductive segment to limit interactions between components that may affect the seal of the housing.

[0042] In some embodiments, the barrier material may be characterized by an annular shape and may define an internal orifice 312 at an inner diameter or within the barrier material structure. Although shown as being centrally positioned, it should be understood that the orifice through which the cathode tab may extend may be positioned anywhere within the structure, such as with an off-center tab. The orifice may also be characterized by any shape or geometry in one or more dimensions, including a rectangular, elliptical, or oblong shape as shown to facilitate cathode tab entry. When centrally positioned, the orifice 312 may at least partially define the inner annular radius of the barrier material 310. Although the orifice may be characterized by any size, as will be described below, in some embodiments, the orifice may be characterized by a size that allows the orifice to be partially or completely covered.

[0043] The barrier material can be characterized by any number of materials that cannot react or interact with the materials of the electrolyte or the electrode active materials of the electrode stack. For example, the barrier material may include any number of polymeric materials and / or adhesive materials, including an adhesive on one side of the barrier material (such as facing the second conductive shell segment) that allows the barrier material to be bonded to the segment. The adhesive can be or include a polymer backing with an applied adhesive. The polymer can be any number of polymers that provide resistivity, structural resilience, hydrophobicity, or flexibility. For example, in some embodiments, a polyimide-backed tape can be used, which can provide a thin film tape that can be flexible and relatively or completely inert to react with components of the electrolyte. Although described as a tape, additional adhesives or sealants can also be used to provide similar protection to the second conductive segment of the shell, and are similarly covered by the present technology.

[0044] The barrier material can provide a physical barrier to materials within the battery cell and can limit interaction with the second conductive section of the housing, which can limit corrosion when operating at the cathode potential. When included, an aperture through the barrier material can create an additional entry path that allows corrosion to occur. Thus, in some embodiments, the aperture can be at least partially or completely covered by aspects of the cathode tab or associated components. Go to Figure 3B , shows a schematic diagram of battery materials according to some embodiments of the present technology, and can illustrate aspects of the cathode tab 212 as previously described. As previously described, the cathode tab 212 can extend from the cathode current collector or electrode and can allow coupling with the second conductive section of the housing.

[0045] The cathode tab 212 may include an actual tab element 350, and it may be any material that can be used for the cathode current collector, and may be the same or compatible material as the cathode current collector 355 and / or the second conductive segment of the housing. The tab element 350 may be characterized by a first surface 352 and a second surface 354 opposite the first surface. The first surface 352 may be configured to couple with the second conductive segment of the housing, and may include an exposed portion as shown. In some embodiments, the conductive tab may be welded or bonded to the cathode current collector 355. Although shown as being coupled to the first surface 352 of the tab element 350, it should be understood that the cathode tab may be coupled to the collector on either side of the tab element. In order to limit the sharp or jagged edges of the feature, one or more insulating tapes or adhesives may be used to cover the tab element 350. The first insulating material 360 may be disposed in contact with the first surface of the tab element 350 and may extend partially along the first surface of the cathode tab. The first insulating material may not completely cover the tab element as shown, which may allow areas of the tab element to be exposed for welding or bonding with the housing segments. Thus, and as will be explained below, the first insulating material 360 may be disposed adjacent to or in contact with the barrier material.

[0046] The cathode tab 212 may also include a second insulating material 365 that may protect the second surface 354 of the cathode tab element 350. The second insulating material may be disposed in contact with the second surface 354 of the tab element and may extend at least partially along the second surface of the cathode tab. The second insulating material may provide additional protection and may be used to limit contact or interaction between the electrode stack and the cathode tab, and may also be used in some embodiments of the present technology to at least partially cover the aperture in the barrier material (when formed). In some embodiments, the first insulating material 360 and the second insulating material 365 may be any number of materials and may be the same or different materials as the barrier material. For example, in some embodiments, the insulating material may also be an adhesive polymer material, such as a polyimide-backed tape, and the adhesive may extend to contact the tab element 350.

[0047] Figure 3CA schematic diagram of a battery material according to some embodiments of the present technology is shown, and an additional view of the cathode tab 212 in a direction facing the first insulating material 360 may be shown. As shown, the cathode tab element 350 may be exposed from the first insulating material 360 along a first surface 352, which may extend along the first surface while exposing a contact surface to allow coupling with a second conductive segment of the housing. In addition, a second insulating material 365 may extend along the second surface of the tab element 350. In some embodiments, the second insulating material 365 may extend beyond the lateral edges of one or more surfaces of the tab element 350, and may extend beyond the lateral dimensions of the exposed portion of the tab element 350 in all directions as shown. In some embodiments, this may allow the second insulating material 365 to contact the barrier material outside the cathode tab.

[0048] Figure 4 A schematic front cross-sectional view of battery materials according to some embodiments of the present technology is shown, and a partial view of a battery cell 400 incorporating a barrier material may be shown. The battery cell 400 may include any features, components, or aspects of any battery cell or component previously described, and may show an electrode stack 405 incorporated within a second conductive housing segment 410. It should be understood that any other components as previously described may be incorporated into some embodiments of the present technology, such as to produce a button cell and any other battery cell structure.

[0049] As shown, the battery cell 400 may include a barrier material 415, which may be any of the previously described barrier materials, and may be disposed along the inner surface of the second conductive segment 410 of the housing. The barrier material 415 may extend radially outward along the outer radius of the electrode stack 405, which may further limit the direct access between the electrode stack and the second conductive segment 410 of the housing. In some embodiments, the barrier material 415 may define an aperture 417 through the barrier material 415, however, in some embodiments, the bonding operation may be performed directly through the barrier material. A conductive tab 420, which may be similar to the previously described conductive tab 212 and may include any of the above components, may extend from the electrode stack 405 and couple a tab element 422 of the conductive tab 420 to the second conductive segment of the housing, such as along the first surface of the tab element 422 as described above. The tab element 422 may extend at least partially within the aperture 417, and a welding, bonding, or other coupling operation may be performed to physically and / or electrically couple the tab element 422 to the housing segment.

[0050] In some embodiments, the first insulating material, as previously described, may or may not extend into or through the aperture 417 and may be positioned in contact with the barrier material 415. In some embodiments, the first insulating material 424 may be a double-sided adhesive material, which may allow the material to be bonded to both the tab element 422, as previously described, and the barrier material 415 in some embodiments. Additionally, the second adhesive material 426 may extend at least partially through or around the aperture 417 of the barrier material, which may limit direct access to the second conductive segment 410 and may reduce or limit corrosion of the surface. Because the same surface of the second insulating material 426 may contact each of the tab element 422 and the barrier material 415, the same adhesive surface may contact and bond the two components.

[0051] Figure 5 A schematic diagram of battery materials according to some embodiments of the present technology is shown, and a top view of a battery cell 400 may be shown, wherein the electrode stack 405 is removed from the view. As shown, a barrier material 415 may be included on the inner surface of the second conductive segment 410 of the housing. As shown in the hidden view below the cathode tab, an aperture 417 may be formed, and a tab element 422 may extend at least partially through the aperture. The tab element 422 may be welded or bonded to the second conductive segment of the housing, such as at one or more locations 505. A second insulating material 426 may extend through the aperture 417 and the tab element 422, which may cover or block any direct access to the surface of the second conductive segment 410, and the tab element may be coupled to the surface of the second conductive segment. As described above, the second insulating material 426 may be a viscous material, which may allow the material to adhere to the barrier material 415 outside the lateral edges of the tab element, and the material may also adhere to the tab element. In some embodiments, this may further ensure a more complete barrier.

[0052] Figure 6A schematic diagram of an insulating material 600 according to some embodiments of the present technology is shown, and changes on the second insulating material previously discussed may be shown. It should be understood that the insulating material 600 may be any second insulating material discussed above. As previously described, according to the embodiments covered by the present technology, the aperture formed through the barrier material may be characterized by any shape or geometry. In some embodiments, a portion of the second insulating material may be shaped similarly to the aperture, which may be advantageous in some embodiments for covering the aperture. For example, the insulating material 600 may be characterized by a body 605 and an end region 610. The body 605 may be sized to accommodate the width of the tab element of the conductive tab, and may be sized to extend a certain amount to the lateral outside of the tab element to provide protection from the edge of the tab. The end region 610 may be shaped to accommodate an aperture defining an inner annular radius of the barrier material. The end region may be characterized by a shape similar to the aperture, and / or may be shaped or sized to easily extend through the aperture to block the path between the inner surface of the conductive segment of the electrode stack and the housing. Insulating material 600 is included as one example of the many variations or geometries of insulating materials encompassed by the present technology, which may be any size or shape in an embodiment.

[0053] In some embodiments of the present technology, the barrier material can be or can include a second insulating material as previously described. For example, in some embodiments, the barrier material can be sized or shaped to contain the cathode tab and extend outwardly beyond the outer edge of the electrode stack. Thus, despite containing the cathode tab, the barrier material can be disposed between the electrode stack and the second conductive segment of the housing. Figure 7 A schematic diagram of a barrier material 700 is shown according to some embodiments of the present technology, which may include a barrier material that is additionally used as a second adhesive material as previously described. A battery cell incorporating the barrier material 700 may include any features, components, or characteristics as previously described.

[0054] As shown, the barrier material 700 may contain and extend through the tab element 710 of the conductive tab, which may otherwise include any aspects of the technology as previously described. As described above, the barrier material 700 may still reside between the electrode stack and the housing of the battery cell and adapt to manufacturing, and the barrier material 700 may include one or more additional features. For example, the barrier material 700 may define an orifice 705, through which the tab element 710 of the cathode tab may extend, or in some embodiments, the uncoated section of the collector may extend through the orifice, and the tab element 710 may be coupled to the orifice. In some embodiments, the configuration may still include a first insulating material 715, which may protect the welding or coupling between the tab element 710 of the conductive tab and the cathode current collector of the battery stack. The barrier material 720 may also include a break, a slit, or a spacing that allows the barrier material 720 to fit around the cathode current collector and then couple with the cathode tab.

[0055] Figure 8 A schematic partial front cross-sectional view of a battery cell 800 according to some embodiments of the present technology is shown, and it may include a barrier material 700 as previously described. It should be understood that any of the additional battery cell components described above and any features, components or characteristics as previously described may also be included in the battery cell 800. For example, the electrode stack 805 may be disposed within a housing, which may include a second conductive segment 810 as previously described. As described above, a barrier material 815 may be included in the structure to limit corrosion. The electrode stack may include a cathode tab, which includes a tab element 820, which may be disposed on the back side of the barrier material 815. In other words, the adhesive surface of the barrier material 815 (when included) may be coupled to the inner surface of the second conductive segment of the housing and the second surface of the tab element as previously described. The barrier material may define a slot or spacing 825, which may allow the barrier material to extend around the tab element and also be positioned between the electrode stack 805 and the cathode tab and / or the second conductive segment of the housing. By utilizing any number of features or components according to the embodiments described above, the present technology may limit or prevent corrosion along exposed areas of the conductive housing while maintaining a coupling location for the cathode tab.

[0056] In the foregoing description, for the purpose of explanation, many specific details are discussed in order to provide an understanding of the embodiments of the present technology. However, it is obvious to those skilled in the art that certain embodiments can be practiced without some of these specific details, or with additional details.

[0057] Several embodiments are disclosed, and those skilled in the art will recognize that multiple modifications, alternative structures, and equivalents may be used without departing from the spirit of the embodiments. In addition, many well-known processes and elements are not described to avoid unnecessarily obscuring the present technology. Therefore, the above description should not be considered to limit the scope of the present technology.

[0058] If a series of values ​​is provided, it should be understood that, unless the context clearly dictates otherwise, each intermediate value of the smallest fraction of the unit of the lower limit between the upper and lower limits of the range is also specifically disclosed. Any narrower range between any stated value or unstated intermediate value in the range and any other stated or intermediate value in the range is covered. The upper and lower limits of these smaller ranges may be independently included in the range or excluded, and any restrictions, no one restriction or both are included in each range of the smaller range are also covered in the technical scope, but are subject to any specifically excluded restrictions in the range. In the case where the range includes one or two limiting ranges, the range excluding one or both of those included limitations is also included. If multiple values ​​are provided in the list, any range covering or based on any of these values ​​is similarly specifically disclosed.

[0059] As used herein and in the appended claims, the singular forms "a", "an", and "the" include plural references unless the context clearly dictates otherwise. Thus, for example, reference to "a material" includes a plurality of such materials and reference to "an element" includes reference to one or more elements and equivalents thereof known to those skilled in the art, and so forth.

[0060] In addition, the words “comprises,” “includes,” and “contains,” when used in this specification and the following claims, are intended to specify the presence of stated features, integers, components, or operations, but they do not preclude the presence or addition of one or more other features, integers, components, operations, acts, or groups.

Claims

1. A rechargeable battery cell comprising: A housing, the housing comprising: a first conductive segment operable at an anodic potential, a second conductive segment operable at a cathodic potential, and a gasket positioned between the first conductive segment and the second conductive segment and configured to hermetically seal the housing; An electrode stack, the electrode stack comprising: an anode, wherein the anode includes an anode tab electrically coupled to the first conductive segment of the housing; a cathode, wherein the cathode includes a cathode tab having a first end extending from the electrode stack and a second end electrically coupled to the second conductive segment of the housing, wherein the cathode tab is characterized by a first surface coupled to the second conductive segment of the housing and a second surface opposite the first surface; a barrier material at least partially disposed between the cathode tab and the second conductive segment of the housing, wherein the cathode tab is electrically coupled to the second conductive segment of the housing through the barrier material; a first insulating material extending partially along a first surface of the cathode tab; and a second insulating material in contact with the second surface of the cathode tab, wherein: The second insulating material extends from the first end of the cathode tab beyond the second end of the cathode tab; and The second insulating material is in contact with the barrier material outside the cathode tab.

2. The rechargeable battery cell of claim 1, wherein the second conductive segment is stainless steel.

3. The rechargeable battery cell of claim 1 , wherein the barrier material is characterized by an annular shape, and wherein the cathode tab is coupled to the second conductive segment of the housing at an aperture defining an inner annular radius of the annular shape of the barrier material.

4. The rechargeable battery cell of claim 3, wherein the aperture is characterized by an oval or rectangular shape. 5 . The rechargeable battery cell of claim 4 , wherein the first insulating material is positioned adjacent to the barrier material.

6. The rechargeable battery cell of claim 3, wherein the second insulating material covers the aperture defining the inner annular radius of the barrier material.

7. The rechargeable battery cell of claim 6, wherein the second insulating material is characterized by an end region shaped to cover the aperture defining the inner annular radius of the barrier material.

8. The rechargeable battery cell of claim 3, wherein the barrier material defines a slit extending radially from the aperture.

9. The rechargeable battery cell of claim 1, wherein the barrier material, the first insulating material, and the second insulating material each comprise similar materials.

10. The rechargeable battery cell of claim 9, wherein the similar material is a viscous polymer material.

11. The rechargeable battery cell of claim 1 , wherein the first insulating material comprises: a first adhesive surface and a second adhesive surface opposite the first adhesive surface; and The first adhesive surface adheres to a first surface of a cathode tab and the second adhesive surface adheres to the barrier material. 12 . The rechargeable battery cell of claim 1 , wherein the second insulating material is adhered to the second surface of the cathode tab and the barrier material.

13. A rechargeable battery cell comprising: A button battery housing, comprising: a first conductive section, a second conductive segment, and a gasket positioned between the first conductive segment and the second conductive segment and configured to seal the button cell housing; An electrode stack, the electrode stack comprising: anode, cathode, where: the cathode comprising a cathode tab having a first end extending from the electrode stack and a second end physically and electrically coupled to the second conductive segment of the housing; and the cathode tab being characterized by a first surface coupled to the second conductive segment of the housing and a second surface opposite the first surface; a barrier material at least partially disposed between the cathode tab and the second conductive segment of the button cell housing, wherein the cathode tab extends through the barrier material and is physically and electrically coupled to the second conductive segment of the housing; a first insulating material extending partially along the first surface of the cathode tab; and a second insulating material in contact with the second surface of the cathode tab, wherein: The second insulating material extends from the first end of the cathode tab beyond the second end of the cathode tab; and The second insulating material is in contact with the barrier material outside the cathode tab.

14. The rechargeable battery cell of claim 13, wherein the barrier material is a material comprising a sticky surface, and wherein the sticky surface extends in contact with the second conductive section of the button cell housing.

15. The rechargeable battery cell of claim 13, wherein the barrier material is characterized by an annular shape, and wherein the cathode tab is coupled to the second conductive segment of the housing at an aperture defining an inner annular radius of the annular shape of the barrier material.

16. The rechargeable battery cell of claim 15, wherein the cathode tab is characterized by a first surface coupled to the second conductive segment of the housing and a second surface opposite the first surface, the rechargeable battery cell further comprising: A first insulating material contacts the first surface of the cathode tab and extends partially along the first surface of the cathode tab.

17. A rechargeable battery cell according to claim 16, wherein the first insulating material is a material including a sticky surface, wherein the sticky surface extends in a manner that contacts the cathode tab, and wherein a surface of the first insulating material opposite to the sticky surface extends in a manner that contacts the barrier material.

18. The rechargeable battery cell of claim 13, wherein the second insulating material is a material comprising a sticky surface, wherein the sticky surface extends in contact with the cathode tab, and wherein an edge region of the sticky surface contacts the barrier material.

19. A rechargeable battery cell comprising: A housing, the housing comprising: a first conductive segment operable at an anodic potential, a second conductive segment operable at a cathodic potential, and a gasket positioned between the first conductive segment and the second conductive segment and configured to hermetically seal the housing; An electrode stack, the electrode stack comprising: an anode, wherein the anode includes an anode tab electrically coupled to the first conductive segment of the housing, a cathode, wherein the cathode includes a cathode tab having a first end extending from the electrode stack and a second end electrically coupled to the second conductive segment of the housing, and wherein the cathode tab is characterized by a first surface coupled to the second conductive segment of the housing and a second surface opposite the first surface; a barrier material containing the cathode tab and disposed between the electrode stack and the second conductive segment of the housing, wherein the cathode tab is electrically coupled to the second conductive segment of the housing through the barrier material; and a first insulating material extending partially along the first surface of the cathode tab; and a second insulating material in contact with the second surface of the cathode tab, wherein: The second insulating material extends from the first end of the cathode tab beyond the second end of the cathode tab; and The second insulating material is in contact with the barrier material outside the cathode tab.

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