Electrochemical cell having a folded electrode and separator, battery including the same, and method of forming same
AssigneesRobert Bosch GmbH, Sion Power Corporation
InventorsThomas Kretschmar, Thomas Wöhrle, Martin Tenzer, Nathan Jessen Crum, Ernest Dezso Botos, Lowell Dale Jones
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Abstract
An electrochemical cell including a folded electrode layer and a folded separator, a battery including the electrochemical cell, and methods of forming the electrochemical cell and battery are disclosed. The electrode layer is folded in a first direction and the separator is folded in a second direction, such that the first direction and second direction are orthogonal each other.
Claims53
An electrochemical cell comprising:
- a first electrode layer;
- a separator layer proximate the first electrode layer, the separator layer folded back upon itself in a first direction to form a first separator section, a second separator section and an opening there between;
- and
- a second electrode plate, wherein the plate is between the first separator section and the second separator section,
- wherein the first electrode layer is folded over the separator layer in a second direction which is orthogonal to the first direction to form a first first electrode section underlying the first separator section and a second first electrode section overlying the second separator section.
A method of forming an electrochemical cell, the method comprising the steps of:
- placing a separator layer overlying a first section of a first electrode layer, in a direction orthogonal to the first electrode layer;
- folding the separator layer back onto itself to form a first separator section, a second separator section, and a first opening there between;
- folding the first electrode layer over the second separator section to form a first first electrode section underlying the first separator section and a second first electrode section overlying the second separator section;
- and
- placing a first sheet comprising second electrode material within the opening.
An electrochemical cell comprising:
- a first electrode layer comprising a first electrode section;
- a second electrode layer overlying the first electrode layer, the second electrode layer comprising a first surface and a second surface comprising active material;
- and
- a separator layer partially overlying the second surface,
- wherein a combination of the second electrode layer and the separator layer is folded back over itself in a first direction, the first electrode layer is folded over the combination in a second direction to form a second first electrode section, and wherein the first direction and the second direction are orthogonal each other.
A method of forming an electrochemical cell, the method comprising the steps of:
- placing a combination of a second electrode layer and a separator layer overlying a first first electrode section of a first electrode layer, the combination in a direction orthogonal to the first electrode layer;
- folding the combination back onto itself to form a first combination section and a second combination section;
- and
- folding the first electrode layer over the second combination section to form a second first electrode section overlying the second combination section.
An electrochemical cell comprising:
- a first electrode layer;
- a second electrode layer overlying the first electrode layer, the second electrode layer comprising a first surface comprising active material and a second surface comprising active material;
- a first separator layer partially overlying the first surface;
- and
- a second separator layer partially overlying the second surface,
- wherein a combination of the first separator layer, the second electrode layer, and the second separator layer overlays a first first electrode section, and
- wherein the first electrode layer is orthogonally folded over the combination to form a second first electrode section.
A method of forming an electrochemical cell, the method comprising the steps of:
- placing a combination of a first separator layer, a second electrode layer, and a second separator layer overlying a first first electrode section of a first electrode layer, in a direction orthogonal to the first electrode layer;
- and
- folding the first electrode layer over the combination in a direction orthogonal to the combination.
Dependencies are inferred from the claim text.