Cross-woven electrode assembly

An electrode assembly comprising

• a positive electrode, and
• a negative electrode, wherein
• the positive electrode comprises a first substrate formed of a first electrically-conductive material, the positive electrode having a first active material disposed on both sides of the first substrate,
• the negative electrode comprises a second substrate formed of a second electrically-conductive material, the negative electrode having a second active material disposed on both sides of the second substrate,
• one of the positive electrode and the negative electrode is disposed between a first separator and a second separator to form an insulated electrode,
• opposed lengthwise edges of each of the first substrate and the second substrate are periodically notched and tabs are formed along the lengthwise edges between adjacent notches, and for each of the positive electrode and the negative electrode the notches on one lengthwise edge are offset along the length direction from the notches of an opposed lengthwise edge, and the tabs are electrically conductive and free of active material,
• the insulated electrode is arranged in z-folds about first fold lines that are parallel to a first axis,
• the other of the positive electrode and the negative electrode is arranged in z-folds about second fold lines that are parallel to a second axis, and the second axis is perpendicular to the first axis,
• the insulated electrode is cross-woven with the other of the positive electrode and the negative electrode such that portions of the insulated electrode between adjacent first fold lines are stacked in an alternating manner with portions of the other of the positive electrode and the negative electrode between adjacent second fold lines to form an assembly of the portions that is stacked along a third axis that is perpendicular to both the first axis and the second axis.

An electrochemical cell including

• a cell housing, and
• an electrode assembly disposed in the cell housing, the electrode assembly including
• a positive electrode, and
• a negative electrode,
• wherein
• the positive electrode comprises a first substrate formed of a first electrically-conductive material, the positive electrode having a first active material disposed on both sides of the first substrate,
• the negative electrode comprises a second substrate formed of a second electrically-conductive material, the negative electrode having a second active material disposed on both sides of the second substrate,
• one of the positive electrode and the negative electrode is disposed between a first separator and a second separator to form an alpha electrode, and the other one of the positive electrode and the negative electrode forms a beta electrode,
• opposed lengthwise edges of each of the alpha electrode and the beta electrode are periodically notched and tabs are formed along the lengthwise edges between adjacent notches, and for each of the alpha electrode and the beta electrode, the notches on one lengthwise edge are offset alone the length direction from the notches of an opposed lengthwise edge, and the tabs are electrically conductive and free of active material,
• the alpha electrode is arranged in a series of z folds in which the alpha electrode is folded in a first direction about an axis parallel to a first fold axis so that a second portion of the alpha electrode overlies a first portion of the alpha electrode, and folded in a second direction about another axis parallel to the first fold axis so that a third portion of the alpha electrode overlies the first portion of the alpha electrode, the first direction being opposed to the second direction, and the first portion of the alpha electrode, the second portion of the alpha electrode, and the third portion of the alpha electrode being arranged in a stacked configuration defining a stack axis,
• the beta electrode is arranged in a series of z folds in which the beta electrode is folded in a third direction about an axis parallel to a second fold axis so that a second portion of the beta electrode overlies a first portion of the beta electrode, and folded in a fourth direction about another axis parallel to the second fold axis so that a third portion of the beta electrode overlies the first portion of the beta electrode, the third direction being opposed to the fourth direction, and the second fold axis being perpendicular to the first fold axis and the stack axis,
• the z folds of the alpha electrode are woven with the z folds of the beta electrode such that the first, second and third portions of the beta electrode are stacked along the stack axis so as to alternate with the first, second and third portions of the alpha electrode.

A method of forming an electrode assembly comprising a positive electrode, and a negative electrode,

• the positive electrode comprises a first substrate formed of a first electrically-conductive material, the positive electrode having a first active material disposed on both sides of the first substrate,
• the negative electrode comprises a second substrate formed of a second electrically-conductive material, the negative electrode having a second active material disposed on both sides of the second substrate,
• wherein the method includes
• disposing one of the positive electrode and the negative electrode between a first separator and a second separator to form an alpha electrode, and using the other one of the positive electrode and the negative electrode to form a beta electrode,
• arranging the alpha electrode in a first series of z folds,
• while arranging the alpha electrode in the first series of z-folds, also arranging the beta electrode in a second series of z folds that is interwoven with the first series of z-folds to provide an electrode stack in which portions of the beta electrode are stacked along a stack axis so as to alternate with portions of the alpha electrode, and
• wherein
• opposed lengthwise edges of each of the alpha electrode and the beta electrode are periodically notched and tabs are formed along the lengthwise edges between adjacent notches, and for each of the alpha electrode and the beta electrode, the notches on one lengthwise edge are offset along the length direction from the notches of an opposed lengthwise edge, and the tabs are electrically conductive and free of active material.