Chemistry: electrical current producing apparatus – product – and – Current producing cell – elements – subcombinations and... – Plural cells
Reexamination Certificate
1999-12-01
2001-09-25
Maples, John S. (Department: 1745)
Chemistry: electrical current producing apparatus, product, and
Current producing cell, elements, subcombinations and...
Plural cells
C429S127000, C429S162000
Reexamination Certificate
active
06294288
ABSTRACT:
FIELD OF THE INVENTION
This invention relates to a battery cell and a method for producing the same.
BACKGROUND OF THE INVENTION
A battery cell typically includes a separator material sandwiched between two oppositely-charged electrodes. The oppositely-charged electrodes are generically referred to as an electrode and a counter electrode. The term electrode identifies either a positive (cathodic) electrode or a negative (anodic) electrode and the term counter electrode identifies the other electrode.
A battery bi-cell typically includes at least three electrodes layered in an electrode/counter electrode/electrode or counter electrode/electrode/counter electrode relationship. Separator material can be included in the electrode and/or counter electrode of the bi-cell.
Polymer film batteries are commonly constructed from one or more cells or bi-cells. The bi-cells are normally arranged in a stack and enclosed in a battery package. A positive terminal strip and negative terminal strip extend outward from the package. Each bi-cell typically includes at least one electrode tab and at least one counter electrode tab connecting the bi-cell to each respective battery terminal strip. In this manner, the electrode and counter electrode tabs provide a circuit for charging and discharging the battery. In most applications, it is desirable to encase the battery in the smallest possible package. As a result, gathering the electrode and counter electrode tabs from each bi-cell and routing such tabs to the respective battery terminal strips within a small battery package presents difficulties.
Conventional electrode tab designs used in parallel plate cell constructions have several shortcomings. Such tab designs produce a bi-cell having loose internal component tolerances, inefficient volumetric utilization of the battery package geometry, and a fragile mechanical structure.
Further, conventional bi-cell manufacturing methods also have several shortcomings. Such bi-cell fabrication methods are complex, wasteful of material, and require a large number of tolerancing and alignment steps. Accordingly, it would be desirable to provide a cell design and method of producing the same which overcome the shortcomings of the prior art.
SUMMARY OF THE INVENTION
The present invention provides a battery cell including an electrode having an area defined by a perimeter including an edge, a counter electrode having an area defined by a perimeter including an edge, and a separator having an area defined by a perimeter including an edge. The separator is sandwiched between the electrode and the counter electrode in a layered relationship with at least portions of the edges being contiguous. The separator and one of the electrode and the counter electrode each include a first notch in the edge exposing a portion of the other of the electrode and counter electrode.
The separator and the other of the electrode and the counter electrode each include a second notch in the edge exposing a portion of the one of the electrode and the counter electrode.
A method of producing a battery cell in accordance with the present invention is also provided. The cell includes a plurality of film layers, a plurality of current collector layers, and at least one separator layer. Each current collector layer includes a predetermined lead portion. The method includes the steps of: providing at least one notch in each layer, and stacking the layers with the notches arranged with one another to expose the predetermined lead portion of each current collector layer.
These and other objects, features, and advantages will become apparent from the following description of the preferred embodiments, claims, and accompanying drawings.
REFERENCES:
patent: 5460904 (1995-10-01), Gozdz et al.
patent: 5587253 (1996-12-01), Gozdz et al.
patent: 6030721 (2000-02-01), Lake
patent: 4-332462 (1992-11-01), None
patent: 5-234598 (1993-09-01), None
patent: 6-260172 (1994-09-01), None
patent: 10-270014 (1998-10-01), None
patent: WO 99/36971 (1999-07-01), None
patent: WO 00/72392 A1 (2000-11-01), None
International Search Report PCT/US 00/30270, Feb., 2001.
Harness & Dickey & Pierce P.L.C.
Maples John S.
Valence Technology Inc.
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