U-Fold Electrode Structure for Implantable Medical Device Cells

The patent combines multiple separate electrode layers into a single integrated electrode structure with alternating active and collector regions. This merging eliminates the need for multiple separate interconnections between layers, reducing manufacturing complexity while maintaining the stacked configuration's volumetric efficiency. The single electrode structure can be manufactured as one piece using techniques like photolithography and etching, avoiding the assembly of multiple separate components.

By integrating multiple electrode layers into a single continuous electrode structure, the patent eliminates the interfaces between separate layers that cause tolerance stack-up. The single-piece construction ensures precise control over electrode material distribution and thickness without accumulation of manufacturing tolerances from multiple assembly steps, thereby maintaining electrode material balance more reliably.

The patent merges multiple separate lithium foil pieces into a single continuous electrode structure where active and collector regions are integrated. This approach maintains the reduced interconnection benefit of serpentine designs while eliminating the need to manufacture and assemble multiple pieces of different thicknesses, as the varying thickness regions are created in a single manufacturing process through photolithography and etching.

The patent incorporates three-dimensional features within the flat cell structure, including protruding and recessed regions that create internal surface area for heat dissipation. The electrode structure includes active regions that protrude toward the separator and collector regions that recess, creating a multi-level topology that increases effective heat transfer surface area without increasing the overall footprint of the flat cell, thus addressing heat dissipation challenges while maintaining volumetric efficiency.