Cell with tabless structure electrode

Abstract

To provide: a cell of an energy storage device; an energy storage device; a method for forming the cell; and a method of forming the energy storage device.SOLUTION: A cell of an energy storage device with at least one electrode that is tabless, and methods of forming the same, are described. The cell 100 includes a first substrate 102 having a first coating 110 disposed thereon, where a second portion 116 of the first substrate at a proximal end along the width of the first substrate comprises a conductor. An inner separator 104 is disposed over the first substrate. A second substrate 106 is disposed over the inner separator. The second substrate has a second coating 120 disposed thereon. The first substrate, the inner separator and the second substrate are in a successive manner, and the first substrate, the inner separator and the second substrate are rolled about a central axis AA'.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] [Incorporation by Reference of Priority Application] This application claims priority to U.S. Provisional Patent Application No. 62 / 755,68 5, filed on November 5, 2018, the entire disclosure of which is hereby incorporated by reference in its entirety. Background

[0002] The present disclosure relates to cells for energy storage devices.

Background Art

[0003] Currently, many types of battery cells are used as energy sources in electric vehicles and energy storage applications. Current cells use a jelly roll design in which a cathode, an anode, and a separator are wound together and have cathode tabs and an ode tabs for connection to the positive and negative terminals of the cell can. The current path necessarily proceeds through these tabs to a connector outside the battery cell. However, when the current has to flow along the cathode or anode to the tab and out of the cell, the ohmic resistance increases with distance. Further, since the tabs are additional components, they increase the cost and present manufacturing challenges.

Summary of the Invention

Means for Solving the Problems

[0004] To summarize the advantages achieved over the prior art and the present invention, this specification describes certain objectives and advantages of the present invention. Not all of such objectives or advantages may be achieved in any particular embodiment of the present invention. Thus, for example ​​​​​​ then one of ordinary skill in the art will recognize that the present invention may be embodied or carried out in a manner that achieves or optimizes other objects or advantages that may be taught or suggested herein without necessarily achieving one advantage or group of advantages as taught herein.

[0005] In one aspect, a cell of an energy storage device is described. The cell includes a first substrate having a first coating, where a second portion of the first substrate at a proximal end along the width of the first substrate includes a conductor, the first substrate, a second substrate having a second coating, and an inner separator disposed between the first substrate and the second substrate, and the first substrate, the inner separator, and the second substrate are wound around a central axis to form the cell.

[0006] In some embodiments, the conductor is essentially composed of the first substrate. In some embodiments, the first substrate is a current collector. In some embodiments, when wound, the first substrate is aligned closest to the central axis. In some embodiments, when wound, the second substrate is aligned closest to the central axis.

[0007] In some embodiments, a first portion of the first substrate positioned midway along the width of the first substrate is coated with an electrically insulating material. In some embodiments, the second portion is positioned adjacent to the first portion. In some embodiments, the second substrate further includes a conductive tab. In some embodiments, the conductive tab is disposed midway along the length of the second substrate and extends across the central plane of the second substrate. In some embodiments, the first substrate ​​forms one of the anode and the cathode, and the second substrate forms the other of the anode and the cathode.

[0008] In another aspect, an energy storage device is described. The energy storage device comprises a cell of the energy storage device and a can having a first end and a second end, and the first end comprises a first cap having a contact surface.

[0009] In some embodiments, the conductor is in electrical contact with the contact surface. In some embodiments, the first end comprises a bottom wall. In some embodiments, the first and second ends are each open ends and. In some embodiments, the first end of the can is configured to receive the first cap and. In some embodiments, the second end of the can is configured to receive the second cap and. In some embodiments, the first cap comprises at least one of nickel (Ni) and Ni-based alloys and. In some embodiments, the contact surface of the first cap comprises a helical-shaped groove.

[0010] In another aspect, a method for forming a cell is described. The method includes providing a first substrate comprising a first coating, wherein a second portion of the first substrate proximal to the width of the first substrate comprises a conductor, disposing an inner separator on the first substrate, providing a second substrate comprising a second coating, disposing the second substrate on the inner separator, and winding the first substrate, the inner separator, and the second substrate disposed on top of each other around a central axis to form a cell.

[0011] In some embodiments, the position of the first substrate is closest to the central axis. In some embodiments, the position of the second substrate is closest to the central axis. In some embodiments, the first substrate, the inner separator and the second substrate are arranged continuously on top of each other.

[0012] In some embodiments, the method further includes coating a first portion of the first substrate positioned midway along the width of the first substrate with an electrically insulating material. In some embodiments the second portion is positioned adjacent to the first portion. In some embodiments, the method further includes forming a conductive tab midway along the length of the second substrate by extending a portion of the second substrate across the central plane of the second substrate. In another aspect, a method of forming an energy storage device is described. The method includes forming a cell and placing the cell into a can having a first end and a second end, the first

[0013] end having a first cap with a contact surface. In some embodiments, the method further includes electrically connecting a conductor to the contact surface.

[0014]

[0015] All of these embodiments are intended to be included within the scope of the invention disclosed herein. These and other embodiments of the present invention will be readily apparent to those skilled in the art from the following detailed description of the preferred embodiments with reference to the accompanying drawings, but the present invention is not limited to any specific preferred embodiment disclosed.

Brief Description of the Drawings

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[0032] The embodiments of the present disclosure and their corresponding advantages will be best understood by referring to the following detailed description. Similar reference numerals are used to identify similar elements illustrated in one or more of the drawings, and it should be recognized that the figures shown in the drawings are for purposes of exemplifying the embodiments of the present disclosure and not for limiting the present disclosure. Similar reference numerals are used to identify similar elements illustrated in one or more of the drawings, and it should be recognized that the figures shown in the drawings are for purposes of exemplifying the embodiments of the present disclosure and not for limiting the present disclosure. Similar reference numerals are used to identify similar elements illustrated in one or more of the drawings, and it should be recognized that the figures shown in the drawings are for purposes of exemplifying the embodiments of the present disclosure and not for limiting the present disclosure. Similar reference numerals are used to identify similar elements illustrated in one or more of the drawings, and it should be recognized that the figures shown in the drawings are for purposes of exemplifying the embodiments of the present disclosure and not for limiting the present disclosure. Similar reference numerals are used to identify similar elements illustrated in one or more of the drawings, and it should be recognized that the figures shown in the drawings are for purposes of exemplifying the embodiments of the present disclosure and not for limiting the present disclosure.

DETAILED DESCRIPTION OF THE INVENTION

[0033] The present disclosure relates to cells for energy storage devices. More specifically, the present disclosure relates to cells having at least one electrode that is tabless, and thus can be used to form an energy storage device with reduced ohmic resistance and reduced cost. For example, within a jelly roll cell design, the negative electrode may include a conductive portion that extends along the length of the electrode and connects to the bottom of the can at one end to electrically connect the electrode to the can. Depending on the embodiment, the can may include a cap having a specific design configured to increase the connection between the electrode and the cap. The cap may include ridges, bumps, cavities, or other features that provide additional connection between the cap and the electrode. The present disclosure relates to cells having at least one electrode that is tabless, and thus can be used to form an energy storage device with reduced ohmic resistance and reduced cost. For example, within a jelly roll cell design, the negative electrode may include a conductive portion that extends along the length of the electrode and connects to the bottom of the can at one end to electrically connect the electrode to the can. Depending on the embodiment, the can may include a cap having a specific design configured to increase the connection between the electrode and the cap. The cap may include ridges, bumps, cavities, or other features that provide additional connection between the cap and the electrode. The present disclosure relates to cells having at least one electrode that is tabless, and thus can be used to form an energy storage device with reduced ohmic resistance and reduced cost. For example, within a jelly roll cell design, the negative electrode may include a conductive portion that extends along the length of the electrode and connects to the bottom of the can at one end to electrically connect the electrode to the can. Depending on the embodiment, the can may include a cap having a specific design configured to increase the connection between the electrode and the cap. The cap may include ridges, bumps, cavities, or other features that provide additional connection between the cap and the electrode. The present disclosure relates to cells having at least one electrode that is tabless, and thus can be used to form an energy storage device with reduced ohmic resistance and reduced cost. For example, within a jelly roll cell design, the negative electrode may include a conductive portion that extends along the length of the electrode and connects to the bottom of the can at one end to electrically connect the electrode to the can. Depending on the embodiment, the can may include a cap having a specific design configured to increase the connection between the electrode and the cap. The cap may include ridges, bumps, cavities, or other features that provide additional connection between the cap and the electrode. The present disclosure relates to cells having at least one electrode that is tabless, and thus can be used to form an energy storage device with reduced ohmic resistance and reduced cost. For example, within a jelly roll cell design, the negative electrode may include a conductive portion that extends along the length of the electrode and connects to the bottom of the can at one end to electrically connect the electrode to the can. Depending on the embodiment, the can may include a cap having a specific design configured to increase the connection between the electrode and the cap. The cap may include ridges, bumps, cavities, or other features that provide additional connection between the cap and the electrode. The present disclosure relates to cells having at least one electrode that is tabless, and thus can be used to form an energy storage device with reduced ohmic resistance and reduced cost. For example, within a jelly roll cell design, the negative electrode may include a conductive portion that extends along the length of the electrode and connects to the bottom of the can at one end to electrically connect the electrode to the can. Depending on the embodiment, the can may include a cap having a specific design configured to increase the connection between the electrode and the cap. The cap may include ridges, bumps, cavities, or other features that provide additional connection between the cap and the electrode. The present disclosure relates to cells having at least one electrode that is tabless, and thus can be used to form an energy storage device with reduced ohmic resistance and reduced cost. For example, within a jelly roll cell design, the negative electrode may include a conductive portion that extends along the length of the electrode and connects to the bottom of the can at one end to electrically connect the electrode to the can. Depending on the embodiment, the can may include a cap having a specific design configured to increase the connection between the electrode and the cap. The cap may include ridges, bumps, cavities, or other features that provide additional connection between the cap and the electrode. The present disclosure relates to cells having at least one electrode that is tabless, and thus can be used to form an energy storage device with reduced ohmic resistance and reduced cost. For example, within a jelly roll cell design, the negative electrode may include a conductive portion that extends along the length of the electrode and connects to the bottom of the can at one end to electrically connect the electrode to the can. Depending on the embodiment, the can may include a cap having a specific design configured to increase the connection between the electrode and the cap. The cap may include ridges, bumps, cavities, or other features that provide additional connection between the cap and the electrode.

[0034] Next, refer in detail to the specific embodiments or features illustrated by the accompanying drawings. . Throughout the drawings, wherever possible, corresponding or similar reference numerals are used to denote the same or corresponding parts.

[0035] FIG. 1 shows a cell 100 according to a predetermined embodiment of the present disclosure. In some embodiments, the cell 100 can be rechargeable during discharge and thus can be embodied in the form of a secondary battery that can be used multiple times. In other embodiments, aspects of the present disclosure can similarly be applied to manufacture primary batteries, thereby minimizing the cost of such primary batteries. Primary batteries typically include batteries that are non-rechargeable and thus not suitable for reuse once discharged.

[0036] As shown in FIG. 1, the cell 100 includes a first substrate 102, and a first coating 110 is disposed on one side of the first substrate 102. In some embodiments, the first coating 110 may be disposed on both sides of the first substrate 102. In some embodiments, the first substrate 102 is preferably embodied in the form of a laminate having a predetermined thickness, for example, a thickness in the range of 0.01 to 1 millimeter (mm). In some embodiments, the first substrate 102 includes a current collector. In some embodiments, the current collector includes a metal foil. In some embodiments, the current collector includes aluminum and / or copper.

[0037] In some embodiments, the first coating 110 may be a conductive coating having a first amount of conductivity. In some embodiments, the first coating 110 may be an electrode thin film. In some embodiments, the conductive coating includes an electrode active material. Depending on the form, the electrode active material is a cathode active material. According to an embodiment, the electrode active material is an anode active material. According to an embodiment, the electrode active material is a silicon material (for example, metallic silicon and silicon dioxide), a graphite material, graphite, a graphene-containing material , hard carbon, soft carbon, carbon nanotubes, porous carbon, conductive carbon, lithium nickel manganese cobalt oxide (NMC), lithium manganese oxide (LMO), lithium iron phosphate (LFP), lithium cobalt oxide (LCO), lithium titanate (LTO), lithium nickel cobalt aluminum oxide (NCA), layered transition metal oxides (LiCo O 2 (LCO), Li(NiMnCo)O 2 (NMC) and / or LiNi 0.8 C o 0.15 Al 0.05 O 2 (NCA), etc.), spinel manganese oxides (LiMn 2 O 4 (LMO) and / or LiMn 1.5 Ni 0.5 O 4 (LMNO), etc.), olivine (LiFePO such as), chalcogenides (LiTiS 4 ), tabularite (LiFe 2 )SO SO 4 F), silicon, silicon oxide (SiOx), aluminum, tin, tin oxide (Sn Ox), manganese oxide (MnOx), molybdenum oxide (MoO 2 ), molybdenum disulfide ( MoS 2 ), nickel oxide (NiOx), copper oxide (CuOx), and lithium sulfide (L i 2 S), or a combination thereof. According to an embodiment, the first coating The ring further includes a binder. In some embodiments, the first coating 110 may be disposed on the first substrate 102 by any means known to those skilled in the art. Some examples of disposing the first coating 110 on the first substrate 102 include, but are not limited to, mechanical deposition, electromechanical deposition, electrochemical deposition, or any combination of processes known to those skilled in the art.

[0038] Furthermore, or optionally, a first portion 112 of the first substrate 102 positioned along the width W of the first substrate 102 is coated with an electrical insulating material 114. In some embodiments, the electrical insulating material may be a polymeric insulating material. In some embodiments, the electrical insulating material may be a ceramic insulating material. In some embodiments, the ceramic insulating material includes ceramic powder. In some embodiments, the electrical insulating material is selected from polyethylene, polypropylene, aluminum oxide (e.g., Al 2 O 3 ), or a combination thereof. In some embodiments, the electrical insulating material further includes a binder. In some embodiments, the electrical insulating material 114 may be disposed on both sides of the first substrate 102. In some embodiments, the insulating layer 114 is omitted. In certain embodiments, the first portion 112 of the first substrate 102 may be omitted. In such embodiments, the forming steps required to form the first portion 112 of the first substrate 102 may be omitted, such that, as described below, the first substrate 102 has only the second portion 116. In some embodiments, the electrical insulating material is the first substrate 102, the first co - The coating 110 and / or the conductive portion 118 and the second substrate 106 and / or the second It may be useful to reduce or prevent electrical contact with the coating.

[0039] The second portion 116 of the first substrate 102 is disposed at an extreme or end position (e.g., the proximal end of the first substrate 102) along the width W of the first substrate 102 and is positioned adjacent to the first portion 112. The second portion 116 of the first substrate 102 is provided with a conductive portion (i.e., a conductor) 118. According to an embodiment, the conductive portion 118 is an exposed region (e.g., a current collector) of the first substrate 102. According to an embodiment, the conductive portion 118 is made of or essentially consists of the first substrate 102. According to an embodiment, the conductive portion 118 has no first coating 110 and insulating material 114. According to an embodiment, the conductive portion 118 may be disposed on both sides of the first substrate 102. According to an embodiment, the conductive portion 118 is made of or essentially consists of the first substrate 102. According to an embodiment, the conductive portion 118 has no first coating 110 and insulating material 114. According to an embodiment, the conductive portion 118 may be disposed on both sides of the first substrate 102.

[0040] Furthermore, referring to FIG. 1 and as also shown in FIG. 2, the inner separator 104 is disposed to cover the first substrate 102 (e.g., stacked on top of the first substrate 102). According to an embodiment, the inner separator 104 is in the form of a laminate having a predetermined thickness, e.g., a thickness in the range of 0.01 to 0.05 millimeters (mm). According to an embodiment, the inner separator is 10 μm, 15 μm, 20 μm, 30 μm, 40 μm or 50 μm, or about 10 μm, about 15 μm, about 20 μm, about 30 μm, about 40 μm or about 50 μm, or any value range therebetween (e.g., 10 - 15 μm). Furthermore, according to an embodiment, the inner separator 104 is electrically insulating. m or about 50 μm, or any value range therebetween (e.g., 10 - 15 μm). Furthermore, according to an embodiment, the inner separator 104 is electrically insulating. ​​Yes. In some embodiments, the inner separator may include a polymer material. Embodiments may select the inner separator from polyethylene, polypropylene, or combinations thereof In some embodiments, the inner separator may include a plurality of separator layers In some embodiments, the inner separator includes micropores.

[0041] Continuing to refer to FIG. 1 and as also shown in FIG. 2, the second substrate 106 is disposed to cover the inner separator 104 (e.g., stacked on top of the inner separator 104). A second coating 120 is disposed on one side of the second substrate 106. In some embodiments, the second coating 120 may be disposed on both sides of the second substrate 106. In some embodiments, the second substrate 106 is in the form of a laminate having a predetermined amount of thickness, e.g., in the range of 0.01 to 1 millimeter (mm). In some embodiments, the second substrate 106 includes a current collector (e.g., foil).

[0042] The second coating 120 is a conductive coating having a second amount of conductivity. In some embodiments, the second coating 120 may be an electrode thin film. In some embodiments, the conductive coating includes an electrode active material. In some embodiments, the electrode active material is a cathode active material. In some embodiments, the electrode active material is an anode active material. In certain embodiments, the second coating 120 may be the same as or similar to the first coating 110, and thus may have the same or similar conductivity. In certain other embodiments, the second coating 120 is different from It may be different from the grid 110 and thus may have different conductivity. Depending on the embodiment the second coating 120 may be disposed on the second substrate 106 by any means known to those skilled in the art . The second coating 120 may be disposed on the second substrate 106 . Some examples include, but are not limited to, mechanical deposition, electromechanical deposition, electrochemical deposition, or any combination of processes known to those skilled in the art .

[0043] Continuing to refer to FIG. 1 and as also shown in FIG. 2, the outer separator 108 is disposed to cover the second substrate 106 (e.g., stacked on top of the second substrate 106) . Depending on the embodiment, the outer separator 108 is in the form of a laminate having a predetermined thickness, e.g., a thickness in the range of 0.01 to 0 .05 millimeters (mm). Further, the outer separator 108 is electrically insulating. When the first substrate 102, the inner separator 104, the second substrate 106, and the outer separator 108 are continuously laminated, as best shown in FIG. 1 , the first substrate 102, the inner separator 104, the second substrate 106, and the outer separator 108 are wound around the central axis AA' with the position of the first substrate 102 closest to the central axis AA' . Depending on the embodiment, there is no outer separator 108

[0044] Referring to FIG. 2, a layout 200 of the first substrate 102, the inner separator 104, the second substrate 106, and the outer separator 108 for forming the cell 100 of FIG. 1 is shown . Depending on the embodiment, there is no outer separator 108. In a given embodiment, the inner and outer separators 104, 108 may be of equal length. In this embodiment . wherein the inner and outer separators 104 and 108 each have a length L as shown in FIG. 2 1 have According to an embodiment, the length of the first substrate 102 may be L 2 and the length of the second substrate 106 may be L In a predetermined embodiment, the length L of the first substrate 102 3 may be equal to the length L of the second substrate 106 (i.e., L = L 2 = L 3 ). 2 3 )

[0045] In a predetermined embodiment, the length L of the first substrate 102 2 may be different from, i.e., not equal to, the length L of the second substrate 106 (i.e., L 3 ≠ L 2 ). Further, in some embodiments where the length L of the first substrate 102 3 is not equal to the length L of the second substrate 106 (i.e., L ≠ L 2 ), the length of the inner separator 104 may be shorter than the length of the outer separator 108 3 . According to an embodiment, the length of the inner separator 104 2 ≠ L 3 is shorter than at least one of the first and second substrates 102 and 106, but still provides electrical insulation between the first and second substrates 102 and 106 . Referring still to FIG. 2, in a predetermined embodiment, a portion 202 of the second substrate 106 disposed along the length L of the second substrate 106 may extend laterally with respect to the central plane P of the second substrate 106 to form a conductive tab 122

[0046] In FIGS. 1 and 2 3 to the second substrate 106 may extend laterally with respect to the central plane P of the second substrate 106 to form a conductive tab 122 ​One conductive tab 122 associated with the second substrate 106 is shown, but according to embodiments there may be additional conductive tabs 122 on the second substrate 106. In other embodiments a plurality of discrete portions of the second substrate 106 may extend laterally with respect to the central plane P of the second substrate 106 to form a plurality of conductive tabs 122. Thereby, when such a plurality of conductive tabs 122 are present on the second substrate 106, the ohmic resistance of the cell 100 is expected to be reduced compared to when one conductive tab 122 is present on the second substrate 106.

[0047] The present disclosure provides many advantages compared to other advanced electrochemical cells that utilize tab contacts for electrically connecting the negative electrode substrate to the can wall in addition to tabs for connecting the positive electrode to the cathode connection. Eliminating the tabs connected to the negative electrode and reorienting the conductive connection to the conductive portion 118 allows the negative electrode to extend along the length of the negative electrode. Thereby, the ohmic resistance from the negative electrode to the can is reduced, the current deviation along the length of the electrode is reduced, the cell life is extended, the joule heating is reduced, and the heat dissipation capacity is increased.

[0048] Equation 1 below describes the relationship between the electrical resistance R (Ω) of a given material and its resistivity ρ (Ω·m), where l (m) and A (m ) are the length and cross-sectional area of the material, respectively. 2 TIFF2025087870000002.tif14137

[0049] The electrical resistance of a given material is directly proportional to its length. In conventional electrochemical cell designs, electrode tab contacts are typically fixed either at the end or in the center of the wound electrode. Thus ​​​​​​​​​ To initiate an electrochemical reaction, the current must reach the active material where the charge transfer reaction occurs, and must travel longitudinally through the electrode current collector. The distance the current travels varies from half the length of the wound electrode when the tab is attached at the midpoint of the electrode to the full length of the electrode when the tab is attached at either end. Embodiments included in the present disclosure can provide a more uniform electrical contact between the electrode current collector and the inner surface of the can. Thus, the maximum distance the current travels is on the order of the height of the electrode as opposed to its length. Depending on the form factor of the cell, the height of the electrode is typically 5% to 20% of its length. Thus, in the case of embodiments of the present disclosure, the ohmic resistance in the negative electrode during the electrochemical cycle can be reduced to 1 / 5 to 1 / 20.

[0050] Also, in the case of an electrochemical cell according to the present disclosure, the current deviation that occurs, i.e., the phenomenon where some electrode regions carry more or less current than other regions over the cycle life of the electrode, can also be significantly reduced. The current preferably travels along the path of least resistance, which, in the absence of other factors, would typically be along the path closest to the tab with the lowest resistance. Current deviation is highly undesirable in an electrochemical cell because it can result in local electrode hotspots where large overpotentials occur, leading to undesirable chemical reactions that shorten the life of the cell. An example of such a reaction is the plating of metallic lithium on the surface of the negative electrode in a lithium-ion cell. The reduced ohmic resistance of the disclosed embodiments provides a cell environment that further promotes uniform current distribution and cell life.

[0051] In addition, embodiments according to the present disclosure also provide heat generation and heat transfer characteristics that are superior to those of conventional electrochemical cell designs. Ohmic heating (W), which is a process of generating heat when an electric current passes through a medium, is given by the following Equation 2. Due to the reduction of the aforementioned electrical resistance R, it can be expected that the ohmic heat generated by the electrochemical cell of the present disclosure is significantly less than that of a cell with a conventional tab design. is given by Equation 2 below. TIFF2025087870000003.tif15137

[0052] Due to the reduction of the aforementioned electrical resistance R, it can be expected that the electrochemical cell of the present disclosure generates significantly less ohmic heat than a cell with a conventional tab design.

[0053] The following Equation 3 describes the relationship between the heat conduction of a conductor and the intrinsic and extrinsic variables of the conductor. is as follows. TIFF2025087870000004.tif15137

[0054] Here, Q (J·s -1 ) is the heat transfer rate, k (W·m -1 ·K -1 ) is the thermal conductivity of the material, A (m 2 ) and d (m) are the geometric dimensions through which heat conduction occurs, and ( T 2 -T 1 ) is the temperature difference across d. In a typical electrochemical cell with a tab design, the occupied area of the contact from the tab to the can is typically small. In the case of the cells of the disclosed embodiments, the occupied area of the contact from the conductive portion 118 to the can is effectively 100% of the cell diameter. As a result, in the disclosed embodiments, heat transfer through the base of the cell, and particularly heat transfer from the negative electrode, is improved due to the increased area where the transfer occurs. The improved heat generation characteristics and heat transfer characteristics facilitate the thermal management of the electrochemical cell. Managing the operating temperature of the cell is typically an essential aspect in optimizing the performance of the cell and extending its service life. In the case of a typical tab-designed electrochemical cell, the occupied area of the contact from the tab to the can is typically small. In the case of the cells of the disclosed embodiments, the occupied area of the contact from the conductive portion 118 to the can is effectively 100% of the cell diameter. As a result, in the disclosed embodiments, heat transfer through the base of the cell, and particularly heat transfer from the negative electrode, is improved due to the increased area where the transfer occurs. The improved heat generation characteristics and heat transfer characteristics facilitate the thermal management of the electrochemical cell. Managing the operating temperature of the cell is typically an essential aspect in optimizing the performance of the cell and extending its service life. ​​ Yes.

[0055] Referring to FIG. 3A, an exemplary setup 300 that can be used for coating the first substrate 102 is depicted. In a given embodiment, when manufacturing the first substrate 102, multiple first substrates 102 can be manufactured by stacking individual first substrates 102 tandemly, side by side, or on top of each other. A portion of each first substrate 102 is coated with a first coating 110. Further, or optionally, an electrical insulating material 114 is coated alongside the first coating 110, i.e., onto the first portion 112 of each first substrate 102, and a conductive portion 118 is coated alongside the first portion 112 of each first substrate 102, i.e., onto the corresponding second portion 116 of each first substrate 102. In some embodiments, the insulating material 214 may be omitted as shown in FIG. 3B. This stacking of multiple first substrates 102 side by side or on top of each other when manufacturing the first substrate 102 can save the time and offset the cost that would otherwise occur if the manufacturer were to form each first substrate 102 using individual sections of the laminate and coat the first portion 112 and the second portion 116 of such individual laminates with an electrical insulating material 114 and a conductor for forming the conductive portion 118, respectively. In some embodiments, the insulating material 214 may be omitted as shown in FIG. 3B. When manufacturing the first substrate 102, this stacking of multiple first substrates 102 side by side or on top of each other can save the time and offset the cost that would otherwise occur if the manufacturer were to form each first substrate 102 using individual sections of the laminate and coat the first portion 112 and the second portion 116 of such individual laminates with an electrical insulating material 114 and a conductor for forming the conductive portion 118, respectively.

[0056] In the drawing of FIG. 3A, three first substrates 102 mounted side by side in tandem with each other are shown wound through an exemplary configuration 300. The illustrated setup 300 positions the first substrate 102 at a predefined location to obtain a first substrate 102 of a desired portion and length. For covering, it includes a roller 302 that can cooperate with a timing mechanism (not shown) and a coating tool 304. The three first substrates 102 can be separated from each other, for example, using a crimped margin (not shown) between adjacent first substrates 102, or by another shearing process performed before the plurality of first substrates 102 enter the exemplary setup 300 of FIG. 3A, or after exiting as a plurality of first substrates 102 of a desired length joined from the exemplary setup 300 of FIG. 3A. According to an embodiment, shearing may occur using a shearing tool when the coating is performed. According to an embodiment, prior to shearing, the coated substrate is fired before shearing by the shearing tool. In a predetermined embodiment, as shown in FIG. 4, a first cap 402 having a contact surface 404 is shown. In a predetermined embodiment, the first cap 402 is made of nickel. In other embodiments, the first cap 402 is made of a Ni-based alloy. The contact surface 404 of the first cap 402 is configured to correspond to and connect to the conductive portion 118 of the wound first substrate 102. According to an embodiment, on the opposite side of the can, an insulating material is disposed to generate a compressive force that ensures good electrical contact is formed between the conductive portion 118 and the first cap 402. The insulating material may be placed on the can or near the positive terminal to generate the compressive force. In other embodiments, the anode is wetted with an electrolyte to pressurize the jelly roll into the can, thereby facilitating the formation of good conductivity between the conductive portion 118 and the first cap 402. According to an embodiment, the conductive substrates 102 are automated using a crimped margin (not shown) between adjacent first substrates 102, or by another shearing process performed before the plurality of first substrates 102 enter the exemplary setup 300 of FIG. 3A, or after exiting as a plurality of first substrates 102 of a desired length joined from the exemplary setup 300 of FIG. 3A. According to an embodiment, shearing may occur using a shearing tool when the coating is performed. According to an embodiment, prior to shearing, the coated substrate is fired before shearing by the shearing tool. substrates 102 are automated using a crimped margin (not shown) between adjacent first substrates 102, or by another shearing process performed before the plurality of first substrates 102 enter the exemplary setup 300 of FIG. 3A, or after exiting as a plurality of first substrates 102 of a desired length joined from the exemplary setup 300 of FIG. 3A. According to an embodiment, shearing may occur using a shearing tool when the coating is performed. According to an embodiment, prior to shearing, the coated substrate is fired before shearing by the shearing tool. substrates 102 are automated using a crimped margin (not shown) between adjacent first substrates 102, or by another shearing process performed before the plurality of first substrates 102 enter the exemplary setup 300 of FIG. 3A, or after exiting as a plurality of first substrates 102 of a desired length joined from the exemplary setup 300 of FIG. 3A. According to an embodiment, shearing may occur using a shearing tool when the coating is performed. According to an embodiment, prior to shearing, the coated substrate is fired before shearing by the shearing tool. substrates 102 are automated using a crimped margin (not shown) between adjacent first substrates 102, or by another shearing process performed before the plurality of first substrates 102 enter the exemplary setup 300 of FIG. 3A, or after exiting as a plurality of first substrates 102 of a desired length joined from the exemplary setup 300 of FIG. 3A. According to an embodiment, shearing may occur using a shearing tool when the coating is performed. According to an embodiment, prior to shearing, the coated substrate is fired before shearing by the shearing tool. substrates 102 are automated using a crimped margin (not shown) between adjacent first substrates 102, or by another shearing process performed before the plurality of first substrates 102 enter the exemplary setup 300 of FIG. 3A, or after exiting as a plurality of first substrates 102 of a desired length joined from the exemplary setup 300 of FIG. 3A. According to an embodiment, shearing may occur using a shearing tool when the coating is performed. According to an embodiment, prior to shearing, the coated substrate is fired before shearing by the shearing tool. substrates 102 are automated using a crimped margin (not shown) between adjacent first substrates 102, or by another shearing process performed before the plurality of first substrates 102 enter the exemplary setup 300 of FIG. 3A, or after exiting as a plurality of first substrates 102 of a desired length joined from the exemplary setup 300 of FIG. 3A. According to an embodiment, shearing may occur using a shearing tool when the coating is performed. According to an embodiment, prior to shearing, the coated substrate is fired before shearing by the shearing tool. substrates 102 are automated using a crimped margin (not shown) between adjacent first substrates 102, or by another shearing process performed before the plurality of first substrates 102 enter the exemplary setup 300 of FIG. 3A, or after exiting as a plurality of first substrates 102 of a desired length joined from the exemplary setup 300 of FIG. 3A. According to an embodiment, shearing may occur using a shearing tool when the coating is performed. According to an embodiment, prior to shearing, the coated substrate is fired before shearing by the shearing tool.

[0057] In a predetermined embodiment, as shown in FIG. 4, a first cap 402 having a contact surface 404 is shown. In a predetermined embodiment, the first cap 402 is made of nickel. In other embodiments, the first cap 402 is made of a Ni-based alloy. The contact surface 404 of the first cap 402 is configured to correspond to and connect to the conductive portion 118 of the wound first substrate 102. In embodiments, on the opposite side of the can, an insulating material is disposed to generate a compressive force that ensures good electrical contact is formed between the conductive portion 118 and the first cap 402. The insulating material may be placed on the can or near the positive terminal to generate the compressive force. In other embodiments, the anode is wetted with an electrolyte to pressurize the jelly roll into the can, thereby facilitating the formation of good conductivity between the conductive portion 118 and the first cap 402. In embodiments, the anode is wetted with an electrolyte to pressurize the jelly roll into the can, thereby facilitating the formation of good conductivity between the conductive portion 118 and the first cap 402. In embodiments, the anode is wetted with an electrolyte to pressurize the jelly roll into the can, thereby facilitating the formation of good conductivity between the conductive portion 118 and the first cap 402. In embodiments, the anode is wetted with an electrolyte to pressurize the jelly roll into the can, thereby facilitating the formation of good conductivity between the conductive portion 118 and the first cap 402. Portion 118 is welded to the first cap 402. In some embodiments, the welding is by laser welding and / or ultrasonic welding. In a particular embodiment, as shown in the depiction of FIG. 4, the contact surface 404 is contoured in the shape of concentric grooves 406. Each of these grooves 406 may have a size in the range of 0.01 to 0.1 millimeters (mm) so as to correspond to the thickness of the first substrate 102, since these grooves 406 connect to the conductive portion 118 of the first substrate 102 that is being wound.

[0058] Referring to FIG. 5, a can 502 is shown that can be used to enclose the first substrate 102, inner separator 104, second substrate 106, and outer separator 108 of the cell 100 using the first cap 402. In some embodiments, the can 502 does not include the outer separator 108 and the conductive portion 118 may connect directly to the can. In one embodiment, the can 502 has a first end 504 and a second end 506. In some embodiments, the first and second ends 504, 506 are each open ends. In some embodiments, the first end 504 of the can 502 is adapted to receive the first cap 402, while the second end 506 of the can 502 is adapted to receive a second cap (not shown) that connects to the conductive tab 122 of the second substrate 106. In some embodiments, at least one of the first end and the second end is closed and the can

[0059] FIG. 6A shows a cross-sectional view of the first end of the can 502 including a cell having a conductive portion 118 in contact with the contact surface 404 of the first 402 and is shown bent when pushed up. If portion 118 is formed at the bottom of the jelly roll, the imperfection (the conductor is not on itself) Thus, the conductive portion 118 and the first cap may be in a folded state or the like. In some embodiments, the conductive portion 118 and the first cap In order to create a more robust connection between the conductive portion Features may be created by removing a portion of the edge of the cell. Although the bottom portion of 100 is shown including a first cap 402, in other embodiments, The first cap 402 is omitted, and instead, the conductive portion 118 of the first substrate 102 is wound. 6B, the can is shown in cross section at the first end of the can with the cells, and in contact with each other and with the cells 100. In some embodiments, the conductive portion 118 is connected to the bottom wall 602 of the conductive portion 118 having a pre-specified width. and a pre-specified distance, for example, a fixed width and In some embodiments, the conductive portions 118 may be spaced apart from one another by a fixed distance. As shown in the cross-sectional view of the cell in FIG. 6D, the width and spacing of the cells gradually increased. 506, as shown in the bottom view of the cell in FIG. 6E. 6.00 and the bottom wall 602 of the casing 601 at a constant width and spaced apart from each other. 7 shows a method 700 for manufacturing the cell 100 according to an embodiment of the present invention. As shown, the method 700 includes providing a first substrate 102 with a first coating 110 thereon. In step 704, the method 700 further includes providing a first substrate 1 7. In step 706, the inner separator 104 is laminated onto the inner separator 102. Method 700 includes providing a second substrate 106 having a second coating 120 disposed thereon. In step 708, method 700 further includes the step of laminating the second substrate 106 over the inner separator 104. In step 710, method 700 further includes the step of laminating an outer separator 108 over the second substrate 106 such that the first substrate 102, the inner separator 104, the second substrate 106, and the outer separator 108 are laminated in a continuous manner. 0 may be omitted, and the can does not include the outer separator 108. In step 712, method 700 includes winding the first substrate 102, the inner separator 104, the second substrate 106, and the outer separator 108 around a central axis (e.g., AA') such that the position of the first substrate 102 is closest to the central axis. In certain embodiments, in accordance with method 700 of FIG. 7 and as shown in the depictions of FIGS. 1 and 2, the first substrate 102 is used to form the anode 124 of the cell 100, while the second substrate 106 is used to form the cathode 126 of the cell 100. However, as shown in FIGS. 8 and 9, the cell 700 according to embodiments of the present disclosure has an anode 124 and a cathode 126 that are reversed, i.e., positioned such that the cathode 126 is closest to the central axis AA'. In response to such a change, the contact surface of the first cap may be changed to appropriately correspond to the conductive portion 118 of the first substrate 102. The depictions of FIGS. 10A - 10D show several alternative configurations of the first cap.

[0060]

[0061] However, as shown in FIGS. 8 and 9, the cell 700 according to embodiments of the present disclosure has an anode 124 and a cathode 126 that are reversed, i.e., positioned such that the cathode 126 is closest to the central axis AA'. In response to such a change, the contact surface of the first cap may be changed to appropriately correspond to the conductive portion 118 of the first substrate 102. The depictions of FIGS. 10A - 10D show several alternative configurations of the first cap. Examples 1002, 1004, 1006, and 1008, and their respective contact surfaces 1003, 1005, 1007, and 1009 are shown. In some embodiments, the first cap is attached to the open end of the can. In some embodiments, the first cap and its corresponding contact surface are the bottom or top wall of the can. In some embodiments, the top ography of the cap may be formed by a stamping process. In some embodiments, to provide better contact between the conductive portion 118 and the first cap, a spring-loaded cantilever mechanism (or a similar mechanism) is present under the disc of the cap to provide an upward force to the contact surface.

[0062] Furthermore, in certain embodiments, the first cap, such as the first cap 1004 shown in the drawing of FIG. 10B, has a cantilever cross-section that further provides elasticity against mechanical shocks and vibrations that the cell 100 may encounter during use. In some embodiments, the first caps shown as 1002, 1004, 1006, and 1008 in FIGS. 10A - 10D may be used. In other embodiments, the contact surfaces 1100, 110 2, 1104, and 1106 shown in the cross-sectional views of the first caps in FIGS. 11A - 11D may define the contour of the first cap in the first cap. These first caps show contact surfaces that are cylindrical, pyramidal, spiked, and other shapes suitable for connecting to the conductive portion 1 18 of the first substrate 102 that is wound. 18.

[0063] The foregoing disclosure does not limit the present disclosure to the precise forms or embodiments disclosed herein. ​​​is not intended to. Therefore, with respect to the present disclosure, various alternative forms, embodiments and / or modifications are contemplated, whether explicitly described or implied herein, in light of the present disclosure. Having thus described embodiments of the present disclosure, those skilled in the art will recognize that changes may be made in form and detail without departing from the scope of the present disclosure.

[0064] In the foregoing specification, the present disclosure has been described with reference to specific embodiments. However, as will be recognized by those skilled in the art, the various embodiments disclosed herein may be modified or otherwise implemented in various other ways without departing from the spirit and scope of the present disclosure. Accordingly, the body of this specification should be regarded as exemplary, and is intended to teach those skilled in the art how to make and use various embodiments of the disclosed battery system. It should be understood that the forms of the disclosure shown and described herein are to be construed as representative forms. For those shown and described herein by way of example, equivalent elements or materials may be substituted. Further, certain features of the present disclosure may be utilized independently of the use of other features, all of which will be apparent to those skilled in the art after having obtained the benefit of this disclosure. The expressions "including", "comprising", "incorporating", "consisting of", "having", "is", etc., used to describe and claim the present disclosure are non-exclusive, i.e., items not explicitly described ems may be included. It is also contemplated that there are items, components or elements that are to be construed as being illustrated. References to the singular should be construed as also relating to the plural.

[0065] Furthermore, the various embodiments disclosed herein are to be construed in an exemplary and illustrative sense and in no event should be construed as limiting the disclosure. References related to joining (e.g., connected, associated, coupled, and the like) are used only to assist the reader's understanding of the disclosure and in particular do not impose any limitation on the position, orientation or usage of the elements disclosed herein. Accordingly, references related to joining should be construed broadly, if at all. Furthermore, such references related to joining may not necessarily imply that two elements are directly connected to each other in some cases.

[0066] Furthermore, all numerical terms such as "first", "second", "one", "another" or any other ordinary and / or numerical-related expressions, but not limited thereto, are to be construed only as identifiers to assist the reader's understanding of the various elements, embodiments, variations and / or modifications of the disclosure and in particular do not impose any limitation on the order or preference of another element, embodiment, variation and / or modification or another element, embodiment, variation and / or modification that is related to or exceeds these.

[0067] Also, one or more of the elements shown in the drawings / figures can be implemented in a more separated or integrated manner as being useful for a particular application or recognized as being possibly removed in a given case ​​

Claims

1. 1. A cell of an energy storage device, comprising: A first substrate having a first coating, the first substrate having a proximal end along a width of the first substrate. a first substrate, wherein a second portion of the first substrate comprises a conductor; a second substrate having a second coating; an inner separator disposed between the first substrate and the second substrate; The first substrate, the inner separator and the second substrate are wound around a central axis. forming a cell of an energy storage device.

2. The cell of claim 1 , wherein the electrical conductor consists essentially of the first substrate.

3. The cell of claim 1 , wherein the first substrate is a current collector.

4. The first substrate is aligned closest to the central axis as it is rolled.

2. The cell according to claim 1.

5. The second substrate is aligned closest to the central axis as it is rolled.

2. The cell according to claim 1.

6. A first portion of the first substrate positioned midway along the width of the first substrate 10. The cell of claim 1, coated with an insulating material.

7. The cell of claim 6 , wherein the second portion is positioned adjacent to the first portion. 。

8. The cell of claim 1 , wherein the second substrate further comprises a conductive tab.

9. The conductive tab is disposed midway along the length of the second substrate and is 9. The cell of claim 8, wherein the cell extends across a mid-plane of the first electrode.

10. The first substrate forms one of an anode and a cathode, and the second substrate 2. The method of claim 1, wherein a plate forms the other of the anode and the cathode. cell.

11. 1. An energy storage device, comprising: A cell according to claim 1; a can having a first end and a second end, the first end including a first contact surface. The energy storage device comprises a cap.

12. The device of claim 11 , wherein the electrical conductor is in electrical contact with the contact surface.

13. The device of claim 11 , wherein the first end comprises a bottom wall.

14. The device of claim 11 , wherein the first and second ends are each open ended.

15. 15. The first end of the canister is configured to receive the first cap. The device described in.

16. The method of claim 11, wherein the second end of the can is configured to receive a second cap. Devices listed.

17. The first cap is made of at least one of nickel (Ni) and a Ni-based alloy. The device of claim 11 .

18. The device of claim 11 , wherein the contact surface of the first cap comprises a spiral-shaped groove. 。

19. 1. A method for forming a cell, comprising: Providing a first substrate having a first coating, the first substrate having a width a second portion of the first substrate at a proximal end along the disposing an inner separator over the first substrate; Providing a second substrate carrying a second coating; placing the second substrate over the inner separator; The first substrate, the inner separator and the second substrate are disposed on top of each other. and c. winding the cell around a mandrel to form a cell.

20. The method of claim 19 , wherein the location of the first substrate is closest to the central axis.

21. The method of claim 19 , wherein the position of the second substrate is closest to the central axis.

22. The first substrate, the inner separator and the second substrate are disposed successively on top of each other.

20. The method of claim 19,

23. A first portion of the first substrate positioned midway along a width of the first substrate is electrically 20. The method of claim 19 further comprising the step of coating with an insulating material.

24. 24. The method of claim 23, wherein the second portion is positioned adjacent to the first portion. Law.

25. Extending a portion of the second substrate across a mid-plane of the second substrate; 20. The method of claim 19, further comprising forming a conductive tab midway along the length of the second substrate. The method described above.

26. 1. A method of forming an energy storage device, comprising:

20. A method according to claim 19, placing the cell into a can having a first end and a second end, the first end being providing a first cap having a contact surface.

27. 27. The method of claim 26, further comprising the step of electrically connecting the electrical conductor with the contact surface. 。

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