Cylindrical electrochemical cell and method of forming same

Abstract

Electrochemical cells and methods of making the same are disclosed. An electrochemical cell may include a cell housing and a cell core. The battery housing may define a tubular battery body extending along a longitudinal axis from a distal end to a proximal end. The battery cell may be disposed in the battery housing. The battery cell may include a wound core extending along the longitudinal axis, a cathode, an anode, a plurality of inner windings, and a plurality of outer windings. The plurality of inner windings may be wound around the winding core and define an inner diameter. The plurality of outer windings may be coiled around the plurality of inner windings and define an outer diameter.

Description

Technical Field

[0001] The present disclosure relates particularly to cylindrical solar cells or electrochemical cells. Background Art

[0002] Cylindrical solar cells or electrochemical cells are generally easy to manufacture and provide robust mechanical stability. Such cylindrical solar cells or electrochemical cells may include an anode, a cathode, and a separator in the form of a strip wound in a spiral or coil. Although typical methods and processes for constructing cylindrical batteries or electrochemical cells are mature and low-cost, such electrochemical cells and methods may result in lower energy density than other battery types due to spaces or gaps formed during construction. Summary of the invention

[0003] As described herein, a winding core that forms part of an electrochemical cell can be used to achieve cylindrical batteries and electrochemical cells with increased energy density. When the battery core is constructed, the winding core can be used to wind the battery core. When compared to traditional cylindrical batteries and electrochemical cells, such a winding core can allow for tighter winding of battery core components. In addition, the winding core can be used as an interconnect or a current collector.

[0004] The present invention particularly describes an electrochemical cell, which includes a battery housing and a battery core disposed in the battery housing, the battery housing including a tubular battery body extending from a distal end to a proximal end along a longitudinal axis. The battery core may include a winding core extending along the longitudinal axis, a cathode electrode defining a plurality of cathode windings around the longitudinal axis, an anode electrode defining a plurality of anode windings around the longitudinal axis, a plurality of inner windings wound around the winding core and defining an inner diameter, and a plurality of outer windings wound around the plurality of inner windings and defining an outer diameter. Each inner winding in the plurality of inner windings may include a cathode winding in the plurality of cathode windings or an anode winding in the plurality of anode windings. Each outer winding in the plurality of outer windings may include a cathode winding in the plurality of cathode windings and an anode winding in the plurality of anode windings.

[0005] In general, in one aspect, the present disclosure describes a method for forming an electrochemical cell. The method may include providing a winding core extending along a longitudinal axis, coupling a first electrode to the winding core, and winding the first electrode around the winding core to form a partially wound battery core. The partially wound battery core may include a plurality of inner windings defining an inner diameter. The method may also include coupling a second electrode to the partially wound battery core; winding the first electrode and the second electrode around the partially wound battery core to form the battery core. The battery core may include a plurality of inner windings and a plurality of outer windings defining an outer diameter.

[0006] Advantages and additional features of the subject matter of the present disclosure are set forth in the following detailed description, and in part will become apparent to those skilled in the art from that description or may be learned by practicing the subject matter of the present disclosure as described herein, including the following detailed description, claims, and accompanying drawings.

[0007] It should be understood that both the foregoing general description and the following detailed description present embodiments of the subject matter of the present disclosure and are intended to provide an overview or framework for understanding the nature and characteristics of the subject matter of the present disclosure as claimed. The accompanying drawings are included to provide a further understanding of the subject matter of the present disclosure, and the accompanying drawings are incorporated into and constitute a part of this specification. The accompanying drawings show various embodiments of the subject matter of the present disclosure and are used together with the specification to explain the principles and operations of the subject matter of the present disclosure. In addition, the drawings and descriptions are intended to be illustrative only and are not intended to limit the scope of the claims in any way. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] The following detailed description of specific embodiments of the present disclosure may be best understood when read in conjunction with the following drawings, in which:

[0009] Figure 1 is an isometric view of an embodiment of an electrochemical cell;

[0010] Figure 2 yes Figure 1 A cross-sectional view of an electrochemical cell;

[0011] Figure 3 yes Figure 1 and Figure 2 A cross-sectional view of a battery cell of an electrochemical battery;

[0012] Figure 4 yes Figure 1 and Figure 2 A perspective view of a wound core of an electrochemical cell;

[0013] Figure 5 is a perspective view of another embodiment of an electrochemical cell;

[0014] Figure 6 yes Figure 5 A perspective view of a wound core of an electrochemical cell; and

[0015] Figure 7 is a flow chart of an embodiment of a process for determining a charging voltage of a battery.

[0016] Figure 8 is used during the formation of an electrochemical cell Figure 1 and Figure 2 A perspective view of the process of setting up an insulator in an electrochemical cell.

[0017] The schematic diagrams are not necessarily drawn to scale. DETAILED DESCRIPTION

[0018] Reference will now be made in more detail to various embodiments of the subject matter of the present disclosure, some of which are illustrated in the accompanying drawings. The same numbers used in the accompanying drawings refer to the same components and steps. However, it should be understood that the use of numbers to refer to components in a given figure is not intended to limit the components marked with the same numbers in another figure. In addition, the use of different numbers to refer to components in different figures is not intended to indicate that the components with different numbers cannot be the same or similar to the components with other numbers.

[0019] Typically, in wound cylindrical cells and electrochemical cells, a winding core is used to wind the electrode pairs that constitute the cathode and anode. In conventional battery designs, the winding core is temporary and is removed after the electrode coils are formed. However, using a smaller core as an interconnect or current collector in a finished electrochemical cell allows for more efficient use of the volume of the electrochemical cell. In addition, such electrochemical cells can be wound more tightly to reduce voids within the electrochemical cell and reduce lithium plating problems in wound lithium cells.

[0020] An electrochemical cell 100 including a wound core as described herein is depicted in Figure 1 and Figure 2 middle. Figure 1 A side view of an electrochemical cell 100 is shown. Figure 2 A side cross-sectional view of an electrochemical cell 100 is shown. In addition, Figure 3 A side cross-sectional view of a cell 116 of an electrochemical cell 100 is shown, and Figure 4 An isometric view of a wound core 118 of an electrochemical cell 100 is shown. The electrochemical cell 100 may be any suitable electrochemical cell type, such as lithium metal, lithium iron phosphate or lithium iron phosphate (LFP), lithium nickel manganese cobalt oxide (NMC), lithium nickel cobalt aluminum oxide (NCA), lithium titanate, and the like.

[0021] The electrochemical cell 100 includes a battery housing 102 and a battery core 116. The battery housing 102 may include a battery body 104 extending from a distal end to a proximal end along a longitudinal axis 114. As shown, the battery body 104 is a hollow cylinder. However, when viewed from above along the longitudinal axis 114, the battery body 104 may have any suitable shape. For example, the shape of the battery body 104 may be a polygon, an ellipse, or a combination of straight edges and curved edges. The battery body 104 may include one or more materials, such as aluminum, titanium, stainless steel, nickel, nickel-plated iron steel or other suitable materials. In some embodiments, the battery body 104 may include a polymer material.

[0022] The battery body 104 may also include a distal head 106 coupled to the distal end of the battery body 104 and a proximal head 108 coupled to the proximal end of the battery body 104. The distal head 106 and the proximal head 108 may be coupled to the battery body 104, for example, by an adhesive, a welding process, a crimp closure, etc. The distal head 106 and the proximal head 108 may include one or more materials, such as aluminum, stainless steel, nickel, nickel-plated iron steel, or other suitable materials. In some embodiments, the distal head 106 and the proximal head 108 may include a polymer material.

[0023] The electrochemical cell may also include current collectors 110, 112. The current collectors 110, 112 may include one or more conductive materials, such as titanium, aluminum, copper, etc. The current collectors 110, 112 may each be electrically coupled to one of the electrodes of the electrochemical cell 100. In other words, the current collectors 110, 112 may include an anode current collector conductively coupled to the anode electrode 122 and a cathode current collector conductively coupled to the cathode electrode 120. Each of the current collectors 110, 112 may extend through the distal head 106. One or both of the current collectors 110, 112 may be electrically insulated from the distal head 106 and, by extension, from the rest of the battery housing 102 including the battery body 104 and the proximal head 108. When both current collectors 110, 112 are electrically insulated from the battery housing 102, the electrochemical cell 100 may be considered "housing neutral". In other words, the battery housing 102 may float at the electrolyte potential of the electrochemical cell 100.

[0024] The battery core 116 may be disposed in a battery housing. The battery core 116 may include a winding core 118 extending along a longitudinal axis 114, a cathode electrode 120 defining a plurality of cathode windings around the longitudinal axis 114, and an anode electrode 122 defining a plurality of anode windings around the longitudinal axis 114. The battery core 116 may also include a plurality of inner windings defining an inner diameter 124 of the coiled winding core 118. As shown, the plurality of inner windings include a plurality of cathode windings. In some embodiments, the arrangement of the cathode electrode 120 and the anode electrode 122 may be exchanged so that the plurality of inner windings include a plurality of anode windings. In other words, each of the plurality of inner windings may include a cathode winding in the plurality of cathode windings or an anode winding in the plurality of anode windings. The plurality of inner windings may include a cathode electrode 120 or an anode electrode 122, but not both. In other words, the plurality of inner windings do not include any cathode winding in the plurality of cathode windings or any anode winding in the plurality of anode windings. The battery core 116 may also include a plurality of outer windings coiled around the plurality of inner windings and defining an outer diameter 126. Each of the plurality of outer windings may include one cathode winding of the plurality of cathode windings and one anode winding of the plurality of anode windings.

[0025] The winding core 118 may include a conductive tubular body defining an inner cavity 142. The conductive tubular body of the winding core may extend parallel to the longitudinal axis 114. The current collector 110 may be disposed within the inner cavity 142 of the winding core 118 and may extend along or parallel to the longitudinal axis 114. The insulator 130 may be disposed between the winding core 118 and the current collector 110. The tubular body of the winding core 118 may define one or more notches 144 extending parallel to the longitudinal axis 114 from one end of the tubular body toward the other end of the tubular body. The one or more notches 144 may be configured to cooperate with a winding tool. The one or more notches 144 may facilitate the rotation of the winding core 118 during the battery core winding process. The winding core 118 may also include a groove 146 in the outer surface of the tubular body. The groove 146 may extend parallel to the longitudinal axis 114 along at least a portion of the tubular body. The groove 146 may be shaped to receive the current collector 110.

[0026] The cathode electrode 120 may include a strip of conductive material wound around the winding core 118. The cathode electrode 120 may include any one or more materials, such as lithium-metal oxides (e.g., LiCoO2, LiMn2O4, Li(NixMnyCoz)O2, etc.), vanadium oxide, olivine (e.g., LiFePO4), rechargeable lithium oxide, etc. As shown, the cathode electrode 120 is electrically and mechanically coupled to the winding core 118. In addition, the cathode electrode 120 is electrically and mechanically coupled to the current collector 112. Alternatively, the configuration of the cathode electrode 120 and the anode electrode may be switched so that the cathode electrode 120 is electrically and mechanically coupled to the current collector 110 while being electrically insulated from the winding core 118 and the current collector 112. The cathode may be electrically and mechanically coupled to the current collector 110 via an electrode tab. The electrode tab may be integrally formed with or coupled to the cathode electrode 120. Cathode electrode 120 may be electrically and mechanically coupled to any of wound core 118 , current collector 110 , current collector 112 , or electrode tabs by, for example, welding wires, conductive adhesives, solder, and the like.

[0027] The anode electrode 122 may include a strip of conductive material wound around the winding core 118. The anode electrode 122 may include any one or more materials, such as lithium, graphite, lithium alloying materials, intermetallic materials (e.g., alloys), silicon, copper, etc. In some embodiments, the anode electrode 122 may include copper foil. The copper foil may contain metallic lithium. As shown, the anode electrode 122 is mechanically and electrically coupled to the current collector 110 via an electrode tab 121. The electrode tab 121 may be integrally formed with or coupled to the anode electrode 122. Alternatively, the arrangement of the cathode electrode 120 and the anode electrode may be switched so that the anode electrode is mechanically and electrically coupled to the winding core 118 and the current collector 112 while being insulated from the current collector 110. The anode electrode may be electrically and mechanically coupled to any of the winding core 118, the current collector 110, the current collector 112, or the electrode tabs, for example, by welding wires, conductive adhesives, solders, etc.

[0028] The battery core 116 may also include a separator 128 disposed between the cathode electrode 120 and the anode electrode 122. The separator 128 may define a plurality of separator windings around the longitudinal axis 114. In some embodiments, the separator 128 may include a tube that surrounds or "wraps" a portion of one of the cathode electrode 120 or the anode electrode 122. In some embodiments, the separator 128 may include two or more strips disposed on both sides of the cathode electrode 120 or the anode electrode 122. Each of the plurality of outer windings may include a separator 128 disposed between the cathode electrode 120 and the anode electrode 122. The separator 128 may be formed of one or more electrically insulating materials. The separator 128 may include one or more materials, such as polytetrafluoroethylene (PTFE), cellophane, nylon, polyolefins, etc. In addition, the separator may be porous to allow ions to transfer between the cathode electrode 120 and the anode electrode 122 via an electrolyte.

[0029] The electrochemical cell 100 may also include an electrolyte disposed in the cell housing 102. Figure 2 Although not explicitly marked, the electrolyte may generally fill at least a portion of any space inside the battery housing 102 that is not filled by other components of the electrochemical cell 100. The electrolyte may facilitate ion transfer between the cathode electrode 120 and the anode electrode 122. The electrolyte may have an electrical potential. When the current collectors 110, 112 are electrically isolated from the battery housing 102, the battery housing 102 may float under the electrical potential of the electrolyte. The electrolyte may be, for example, one or more of a liquid, a gel, a paste, and the like. The material composition of the electrolyte may depend on the battery type of the electrochemical cell 100. The electrolyte may include, for example, a lithium salt, sulfuric acid, a fluorinated sulfone, or other suitable electrolyte.

[0030] The electrochemical cell 100 may also include various insulators to insulate the conductive components (e.g., the cell housing 102; the current collectors 110, 112; the cathode electrode 120, the anode electrode 122, etc.) from each other. The insulator 130 may be disposed between the wound core 118 and the current collector 110. In some embodiments, the insulator 130 may be a core extruded microtube. The insulator 130 may include one or more insulating materials such as polytetrafluoroethylene (PTFE), polysulfone, etc.

[0031] Additionally, the electrochemical cell 100 may include an insulator cup 132 disposed between the plurality of outer windings and the battery housing 102. In some embodiments, the insulator cup 132 may include a heat shrink material to conform to the shape of the battery core 116. The insulator cup 132 may include, for example, polytetrafluoroethylene (PTFE), polysulfone, etc. One end of the insulator cup 132 may be open.

[0032] The electrochemical cell 100 may also include a coaxial insulator 134. The coaxial insulator 134 may provide an insulating shield between the edges of the plurality of windings and a conductive component such as one of the headers 106, 108 or an interconnect such as the electrode tab 121. The coaxial insulator 134 may include, for example, polytetrafluoroethylene (PTFE), polysulfone, or the like.

[0033] The electrochemical cell 100 may also include a feedthrough insulator 136. The feedthrough insulator 136 may be disposed in one of the headers 106, 108 to electrically insulate the header 106, 108 from electrical interconnects such as the current collectors 110, 112. The feedthrough insulator 136 may include, for example, glass, a ceramic material (e.g., alumina), or other suitable insulating materials.

[0034] exist Figure 5 Another embodiment of an electrochemical cell 200 is depicted in FIG. The electrochemical cell 200 may include Figure 1 and Figure 2 The components and features of the electrochemical cell 100 of FIG. 100 may be modified with some differences and variations as described below. For example, the electrochemical cell 200 includes a winding core 218 including a plurality of pins 219, such as Figure 5 and Figure 6 The winding core 218 is depicted as being formed Figure 6 The battery cells of the electrochemical cell 200 are previously attached to the winding tool 250 .

[0035] Each of the plurality of pins 219 may extend along or parallel to the longitudinal axis of the electrochemical cell 200. Each of the plurality of pins 219 may be in any suitable elongated shape, such as an elongated cylinder, an elongated polyhedron, etc. Each of the plurality of pins 219 may include, for example, titanium, titanium, vanadium, niobium, etc. One or more of the plurality of pins 219 may be electrically coupled and mechanically coupled to one of the electrodes (e.g., cathode electrode or anode electrode) of the electrochemical cell. At least one of the plurality of pins 219 may extend through the head of the electrochemical cell to provide interconnection and act as a collector for one of the electrodes of the electrochemical cell 200. Prior to forming the battery core of the electrochemical cell 200, the plurality of pins 219 may be held together by a winding tool 250. The winding tool 250 may hold the plurality of pins 219 using, for example, epoxy resin, glass, a clamp, etc.

[0036] Another difference between the electrochemical cell 200 and the electrochemical cell 100 is that the electrochemical cell 200 has a "case negative" design. As shown, the anode electrode is electrically and mechanically coupled to the proximal head 208 of the electrochemical cell via the electrode tab 221. Thus, the proximal head 208 can be at or near the potential of the anode electrode of the electrochemical cell. The electrode tab 221 can be coupled to the proximal head 208 by a coupling element 225. The coupling element 225 can include, for example, a clamp, a weld, a conductive adhesive, a solder, etc.

[0037] For forming an electrochemical cell (e.g. Figure 1 and Figure 2 Electrochemical cell 100 or Figure 5 The method or process 300 of the electrochemical cell 200 is depicted in Figure 7 The method 300 may include providing a winding core extending along a longitudinal axis 302. The winding core may include Figures 1 to 4 The winding core 118 or Figure 5 and Figure 6 The winding core 218 is provided.

[0038] The method 300 may include coupling a first electrode to the winding core 304. The first electrode may be a cathode electrode (e.g., Figures 1 to 3 cathode electrode 120) or an anode electrode (e.g., Figures 1 to 3 Anode electrode 122 of the winding core). Coupling the first electrode to the winding core may include conductively and mechanically coupling the first electrode to the winding core. The first electrode may be coupled to the winding core using any one or more suitable techniques. For example, coupling the first electrode to the winding core may include, for example, one or more of the following: welding the first electrode to the winding core, adhering the first electrode to the winding core, welding the first electrode to the winding core, fixing the edge of the first electrode to two or more pins of the winding core (e.g., Figure 5 and Figure 6 A portion of the first electrode is disposed between a plurality of pins 219 of the winding core (eg, Figure 4 In some embodiments, coupling the first electrode to the winding core comprises welding the first electrode to the winding core. In some embodiments, coupling the first electrode to the winding core comprises laser welding the first electrode and the current conductor to the winding core.

[0039] The method 300 may include winding the first electrode around a winding core to form a partially wound battery core including a plurality of inner windings defining an inner diameter 306. To wind the core to form the partially wound battery core, the method 300 may include making one or more notches (e.g., Figure 3 and Figure 4 The core may be provided with one or more notches 144 of the core for engagement with a winding tool. Winding the core may include rotating the winding core around the longitudinal axis using the winding tool. The winding tool may include, for example, a chuck, a spindle, a motor, or any other device or apparatus to hold and rotate the winding core.

[0040] The method 300 may further include placing a separator (eg, Figures 1 to 3 The separator 128 of the embodiment of the present invention is disposed on a portion of the first electrode. Disposing the separator on the portion of the first electrode may include inserting the portion of the first electrode into a separator tube. In some embodiments, before the first electrode is wound around the winding core to form the partially wound battery core, the first separator strip is disposed on a first side of the first electrode and the second separator strip is disposed on a second side of the first electrode.

[0041] The method 300 may include coupling a second electrode to the partially wound battery cell 308. The second electrode may be a cathode electrode (e.g., Figures 1 to 3 cathode electrode 120) or an anode electrode (e.g., Figures 1 to 3 Anode electrode 122 of the partially wound battery cell. Generally, when the first electrode is a cathode electrode, the second electrode can be an anode electrode, and when the first electrode is an anode electrode, the second electrode can be a cathode electrode. Coupling the second electrode to the partially wound battery cell may include inserting an end of the second electrode between two windings of the partially wound battery cell.

[0042] Method 300 may include winding a first electrode and a second electrode around a partially wound battery cell to form a battery cell 310. A battery cell (e.g., Figures 1 to 3 The battery core 116 may include multiple inner windings and multiple outer windings defining an outer diameter.

[0043] The method 300 may also include placing a current collector (eg, Figure 1 and Figure 2The current collector 110 is disposed in the inner cavity of the winding core. In addition, an insulator (e.g., Figure 2 The insulator 130 may be disposed between the current collector and the winding core. The insulator may fill the space between the current collector and the winding core. Figure 8 As depicted, insulator 130 may be inserted into inner cavity 142 such that insulator 130 surrounds current collector 110 and electrically insulates current collector 110 from winding core 118 .

[0044] Method 300 may also include coupling the second electrode to the current collector. The second electrode may be coupled to the current collector using any suitable technique or techniques (e.g., welding) or any other technique for electrically coupling two conductive elements. The second electrode may be on a coaxial insulator (e.g., Figure 2 The coaxial insulator 134 is arranged between the plurality of windings and the electrode tabs and then coupled to the current collector. Figure 8 As depicted, the coaxial insulator 134 can be disposed over the plurality of windings and the winding core 118 while allowing the current collector 110 to pass through an opening in the coaxial insulator 134. After the coaxial insulator 134 is disposed over the plurality of windings and the winding core 118, the electrode tab 121 can contact and electrically couple to the current collector 110 without being electrically coupled to another electrode.

[0045] The method 300 may also include placing the battery cell in an insulator cup (e.g., Figure 2 The battery core is placed in an insulator cup 132 of the insulator cup. Placing the battery core in the insulator cup may include inserting the battery core into the insulator cup. Placing the battery core in the insulator cup may also include applying heat to the insulator cup after the battery core is received in the insulator cup to cause the insulator cup to shrink fit with the battery core.

[0046] The method 300 may also include providing one or more coaxial insulators (eg, Figure 2 The coaxial insulator 134) ends of the battery core are arranged such that the one or more coaxial insulators insulate the edges of the plurality of windings. At least one coaxial insulator may be placed before the battery core is placed in the insulator cup.

[0047] The method 300 may also include placing the battery cell into a battery body (eg, Figure 1 and Figure 2 The method 300 may also include placing a distal head (e.g., Figure 1 and Figure 2 The distal head 106 or Figure 5The method 300 may also include coupling the proximal head (e.g., the distal head 206) to the distal end of the battery body. Coupling the distal head to the battery body may include welding the distal head to the battery body. Figure 1 and Figure 2 The proximal head 108 or Figure 5 The proximal head 208 of the battery body is coupled to the proximal end of the battery body. Coupling the proximal head to the battery body may include welding the distal head to the battery body. The battery body, the distal head, and the proximal head may form a battery housing (e.g., Figure 1 and Figure 2 The method 300 may further include providing an electrolyte in the battery housing.

[0048] The invention is defined in the claims. However, a non-exhaustive list of non-limiting embodiments is provided below. Any one or more of the features of these embodiments may be combined with any one or more features of another embodiment, implementation or aspect described herein.

[0049] Embodiment Ex1: An electrochemical battery, comprising: a battery housing, the battery housing comprising a battery body extending from a distal end to a proximal end along a longitudinal axis; and a battery core, the battery core being disposed in the battery housing, the battery core comprising: a winding core extending along the longitudinal axis; a cathode electrode, the cathode electrode defining a plurality of cathode windings around the longitudinal axis; an anode electrode, the anode electrode defining a plurality of anode windings around the longitudinal axis; a plurality of inner windings, the plurality of inner windings being wound around the winding core and defining an inner diameter, each of the plurality of inner windings comprising one cathode winding among the plurality of cathode windings or one anode winding among the plurality of anode windings; and a plurality of outer windings, the plurality of outer windings being wound around the plurality of inner windings and defining an outer diameter, each of the plurality of outer windings comprising: one cathode winding among the plurality of cathode windings; and one anode winding among the plurality of anode windings.

[0050] Embodiment Ex2: An electrochemical cell according to Embodiment Ex1, wherein the winding core comprises a conductive tubular body defining an inner cavity, the conductive tubular body extending parallel to the longitudinal axis, and wherein the electrochemical cell comprises: a current collector arranged in the inner cavity of the winding core and extending along or parallel to the longitudinal axis; and an insulator arranged between the winding core and the current collector.

[0051] Embodiment Ex3: The electrochemical cell of Embodiment Ex2, wherein the tubular body of the winding core defines one or more notches extending parallel to the longitudinal axis and configured to cooperate with a winding tool.

[0052] Embodiment Ex4: The electrochemical cell of Embodiment Ex2, wherein the current collector is conductively coupled to one of the cathode electrode or the anode electrode.

[0053] Embodiment Ex5: The electrochemical cell according to Embodiment Ex1, wherein each of the plurality of outer windings further comprises a separator disposed between the one cathode winding of the plurality of cathode windings and the one anode winding of the plurality of anode windings.

[0054] Embodiment Ex6: The electrochemical cell of Embodiment Ex1, wherein the plurality of outer windings further comprises a separator surrounding each cathode winding of the plurality of outer windings or each anode winding of the plurality of outer windings.

[0055] Embodiment Ex7: An electrochemical battery according to Embodiment Ex1, wherein the battery housing further comprises: a distal head coupled to the distal end of the battery housing; and a proximal head coupled to the proximal end of the battery housing.

[0056] Embodiment Ex8: According to the electrochemical cell described in Embodiment Ex7, the electrochemical cell also includes: an anode current collector, which is conductively coupled to the anode electrode and extends through the distal head; and a cathode current collector, which is conductively coupled to the cathode electrode and extends through the distal head.

[0057] Embodiment Ex9: The electrochemical cell according to Embodiment Ex1, wherein the electrochemical cell further comprises an electrolyte disposed in the battery housing, and wherein the battery housing floats at the potential of the electrolyte.

[0058] Embodiment Ex10: The electrochemical cell of Embodiment Ex1, wherein the plurality of inner windings does not include any cathode winding of the plurality of cathode windings or does not include any anode winding of the plurality of anode windings.

[0059] Embodiment Ex11: According to the electrochemical cell of embodiment Ex1, the electrochemical cell further comprises an insulator cup disposed between the plurality of outer windings and the battery housing.

[0060] Embodiment Ex12: The electrochemical cell of Embodiment Ex1, wherein the wound core comprises a plurality of pins extending along or parallel to the longitudinal axis.

[0061] Embodiment Ex13: A method for forming an electrochemical cell, the method comprising: providing a winding core extending along a longitudinal axis; coupling a first electrode to the winding core; winding the first electrode around the winding core to form a partially wound battery core, the partially wound battery core comprising a plurality of inner windings defining an inner diameter; coupling a second electrode to the partially wound battery core; and winding the first electrode and the second electrode around the partially wound battery core to form a battery core, the battery core comprising: the plurality of inner windings; and a plurality of outer windings defining an outer diameter.

[0062] Embodiment Ex14: The method according to Embodiment Ex13, further comprising disposing a separator on a portion of the first electrode before winding the first electrode around the winding core to form the partially wound battery core.

[0063] Embodiment Ex15: According to the method described in Embodiment Ex13, the method also includes setting a first separator strip on a first side of the first electrode and setting a second separator strip on a second side of the first electrode before winding the first electrode around the winding core to form the partially wound battery core.

[0064] Embodiment Ex16: According to the method of embodiment Ex13, the method further comprises: disposing a current collector into an inner cavity of the winding core; and disposing an insulator between the current collector and the winding core.

[0065] Embodiment Ex17: According to the method of embodiment Ex16, the method also includes coupling the second electrode to the collector.

[0066] Embodiment Ex18: The method of Embodiment Ex13, wherein coupling the first electrode to the winding core comprises conductively and mechanically coupling the first electrode to the winding core.

[0067] Embodiment Ex19: The method according to Embodiment Ex13, wherein coupling the first electrode to the winding core includes welding the first electrode to the winding core.

[0068] Embodiment Ex20: The method of Embodiment Ex13, wherein coupling the first electrode to the wound core comprises laser welding the first electrode and a current conductor to the wound core.

[0069] Embodiment Ex21: According to the method described in Embodiment Ex13, the method also includes engaging one or more notches of the winding core with a winding tool, the one or more notches extending parallel to the longitudinal axis, and wherein winding the first electrode around the winding core includes rotating the winding core around the longitudinal axis using the winding tool.

[0070] Embodiment Ex22: The method according to embodiment Ex13, further comprising placing the battery cell into an insulator cup.

[0071] Embodiment Ex23: The method according to embodiment Ex13, further comprising disposing the battery core into a battery body extending from a distal end to a proximal end along the longitudinal axis.

[0072] Embodiment Ex24: According to the method described in Embodiment Ex23, the method further includes: coupling a distal head to the distal end of the battery body; and coupling a proximal head to the proximal end of the battery body.

[0073] Unless otherwise specified, all scientific and technical terms used herein have the meanings commonly used in the art. The definitions provided herein are intended to facilitate understanding of certain terms frequently used herein and are not intended to limit the scope of the present disclosure.

[0074] As used herein, the singular forms "a", "an", and "the" include plural referents unless the context clearly indicates otherwise. As used in this specification and the appended claims, the term "or" is generally used in its sense, including "and / or", unless the context clearly indicates otherwise. The term "and / or" refers to one or all of the listed elements or a combination of any two or more of the listed elements.

[0075] The words "preferred" and "preferably" refer to embodiments of the present disclosure that may provide certain benefits in certain circumstances. However, other embodiments may also be preferred under the same or other circumstances. In addition, the recitation of one or more preferred embodiments does not mean that other embodiments are not useful, and is not intended to exclude other embodiments from the scope of the present invention.

[0076] Unless otherwise expressly stated, it is not intended that any method described herein be construed as requiring that its steps be performed in a particular order. Therefore, in the event that a method claim does not actually recite the order in which its steps are to be followed or the steps are not otherwise specifically stated in the claims or specification to be limited to a particular order, no particular order is intended to be inferred. Any recited single or multiple features or aspects in any claim may be combined or substituted with any other recited features or aspects in any other claim or claims.

[0077] It is obvious to those skilled in the art that various modifications and changes can be made to the technology of the present invention without departing from the spirit and scope of the present disclosure. Because those skilled in the art can make modifications, combinations, sub-combinations and changes to the disclosed embodiments that incorporate the spirit and essence of the technology of the present invention, the technology of the present invention should be interpreted as including all things within the scope of the attached claims and their equivalents.

Claims

1. An electrochemical cell, comprising: a battery housing including a battery body extending along a longitudinal axis from a distal end to a proximal end; and A battery core, the battery core is arranged in the battery housing, and the battery core comprises: a winding core extending along the longitudinal axis; a cathode electrode defining a plurality of cathode windings about the longitudinal axis; an anode electrode defining a plurality of anode windings about the longitudinal axis; a plurality of inner windings coiled around the winding core and defining an inner diameter, each of the plurality of inner windings comprising one cathode winding of the plurality of cathode windings or one anode winding of the plurality of anode windings; and a plurality of outer windings coiled around the plurality of inner windings and defining an outer diameter, each of the plurality of outer windings comprising: a cathode winding of the plurality of cathode windings; and An anode winding of the plurality of anode windings.

2. The electrochemical cell of claim 1 , wherein the wound core comprises a conductive tubular body defining an inner cavity, the conductive tubular body extending parallel to the longitudinal axis, and wherein the electrochemical cell comprises: a current collector disposed within the interior cavity of the winding core and extending along or parallel to the longitudinal axis; and An insulator is disposed between the winding core and the current collector.

3. The electrochemical cell of claim 2, wherein the tubular body of the winding core defines one or more notches extending parallel to the longitudinal axis and configured to cooperate with a winding tool.

4. The electrochemical cell of claim 2, wherein the current collector is conductively coupled to one of the cathode electrode or the anode electrode.

5. The electrochemical cell of claim 1, wherein each of the plurality of outer windings further comprises a separator disposed between the one of the plurality of cathode windings and the one of the plurality of anode windings.

6. The electrochemical cell of claim 1, wherein the plurality of outer windings further comprises a separator surrounding each cathode winding of the plurality of outer windings or each anode winding of the plurality of outer windings.

7. The electrochemical cell according to any one of claims 1 to 6, wherein the battery housing further comprises: a distal head coupled to the distal end of the battery housing; and A proximal head is coupled to the proximal end of the battery housing.

8. The electrochemical cell of claim 7, further comprising: an anode current collector conductively coupled to the anode electrode and extending through the distal head; and A cathode current collector is conductively coupled to the cathode electrode and extends through the distal head.

9. The electrochemical cell according to any one of claims 1 to 6, wherein the electrochemical cell further comprises an electrolyte disposed in the cell housing, and wherein the battery housing floats at the electrical potential of the electrolyte.

10. The electrochemical cell of claim 1, wherein the plurality of inner windings does not include any cathode winding of the plurality of cathode windings or does not include any anode winding of the plurality of anode windings.

11. The electrochemical cell of claim 1, further comprising an insulator cup disposed between the plurality of outer windings and the cell housing.

12. The electrochemical cell of claim 1, wherein the wound core comprises a plurality of pins extending along or parallel to the longitudinal axis.

13. A method for forming an electrochemical cell according to any one of claims 1 to 12, the method comprising: providing a winding core extending along a longitudinal axis; coupling a first electrode to the wound core; winding the first electrode around the winding core to form a partially wound battery core, the partially wound battery core including a plurality of inner windings defining an inner diameter; coupling a second electrode to the partially wound battery cell; as well as The first electrode and the second electrode are wound around the partially wound battery core to form a battery core, the battery core comprising: the plurality of inner windings; and A plurality of outer windings define an outer diameter.

14. The method according to claim 13, further comprising: placing a current collector into the inner cavity of the winding core; as well as An insulator is disposed between the current collector and the winding core. 15 . The method of claim 13 , further comprising disposing a separator on a portion of the first electrode before winding the first electrode around the winding core to form the partially wound battery cell.

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