Electrochemical cells and methods of manufacturing the same
Electrochemical cells and methods of making electrochemical cells are described herein. In some embodiments, an apparatus includes a multi-layer sheet for encasing an electrode material for an electrochemical cell. The multi-layer sheet including an outer layer, an intermediate layer that includes a conductive substrate, and an inner layer disposed on a portion of the conductive substrate. The intermediate layer is disposed between the outer layer and the inner layer. The inner layer defines an opening through which a conductive region of the intermediate layer is exposed such that the electrode material can be electrically connected to the conductive region. Thus, the intermediate layer can serve as a current collector for the electrochemical cell.
1. An apparatus, comprising:
a multi-layer sheet for encasing an electrode material of an electrochemical cell, the multi-layer sheet including
an outer layer;
an intermediate layer including a conductive substrate; and
an inner layer formed with a material configured to be thermally bondable to itself, and disposed on a portion of the conductive substrate, the intermediate layer being disposed between the outer layer and the inner layer,
the inner layer defining an opening through which a conductive region of the intermediate layer is exposed such that the electrode material can be electrically connected to the conductive region.
2. The apparatus of claim 1 , wherein the opening is a first opening, the conductive region is a first conductive region, the inner layer defining a second opening such that a second conductive region of the intermediate layer is exposed, the second conductive region being disposed at a non-zero distance from the first conductive region.
3. The apparatus of claim 1 , wherein the inner layer defines a plurality of openings including the opening, the plurality of openings exposing a plurality of conductive regions of the intermediate layer including the conductive region.
4. The apparatus of claim 1 , wherein the outer layer is a heat resistant film.
5. The apparatus of claim 1 , wherein the outer layer is a polyamide material.
6. The apparatus of claim 1 , wherein the conductive substrate includes at least one of aluminum and copper.
7. The apparatus of claim 1 , wherein the inner layer includes a cast polypropylene material.
8. An apparatus, comprising:
a casing for an electrode material of an electrochemical cell, the casing including a multi-layer sheet including a first layer and a second layer, the second layer including a conductive material, the second layer including a first portion and a second portion, the first layer disposed on the first portion of the second layer but not the second portion,
the multi-layer sheet defining a cavity configured to receive the electrode material that can be electrically connected to the conductive material of the second portion of the second layer; and
a separator coupled to a portion of the first layer and enclosing the cavity.
9. The apparatus of claim 8 , wherein the casing includes a third layer, the second layer being disposed at least partially between the first layer and the third layer.
10. The apparatus of claim 8 , wherein the second layer includes an angled wall portion that at least partially defines the cavity.
11. The apparatus of claim 8 , wherein the second layer includes an angled wall portion at least partially defining the cavity, the first layer being disposed on at least a portion of the angled wall portion.
12. The apparatus of claim 8 , wherein the first layer is a frame member disposed on a periphery portion of the second layer, the first portion of the second layer being the periphery portion.
13. The apparatus of claim 8 , wherein the first layer includes a cast polypropylene material.
14. The apparatus of claim 8 , wherein the conductive substrate includes at least one of aluminum and copper.
15. The apparatus of claim 8 , wherein the cavity is a first cavity, the electrode material being a first electrode material, the multi-layer sheet being a first multi-layer sheet, the apparatus further comprising:
a second multi-layer sheet including a first layer and a second layer, the second layer of the second multi-layer sheet including a conductive material, the second layer of the second multi-layer sheet including a first portion and a second portion, the first layer of the second multi-layer sheet disposed on the first portion of the second layer of the second multi-layer sheet but not the second portion of the second layer of the second multi-layer sheet;
the second multi-layer sheet defining a second cavity configured to receive a second electrode material configured to be electrically connected to the conductive material of the second portion of the second layer of the second multi-layer sheet, the separator disposed between the first multi-layer sheet and the second multi-layer sheet.
16. The apparatus of claim 15 , wherein the second layer of the first multi-layer sheet includes a copper material and the second layer of the second multi-layer sheet includes an aluminum material.
17. The apparatus of claim 8 , wherein the first layer has an outer perimeter, the second layer includes at least a portion that extends outside of the outer perimeter of the first layer such that the at least a portion of the second layer an be used as a terminal for the electrode material.
18. The apparatus of claim 8 , wherein the second layer includes at least one raised portion formed in the second portion of the second layer.
19. An apparatus, comprising:
a first multi-layer sheet having a first layer defining an opening, a second layer formed with an electrically conductive material and a third layer, the second layer disposed between at least a portion of the first layer and at least a portion of the third layer such that a portion of the second layer is exposed through the opening of the first layer;
a second multi-layer sheet having a first layer defining an opening, a second layer formed with an electrically conductive material and a third layer, the second layer of the second multi-layer sheet disposed between at least a portion of the first layer of the second multi-layer sheet and at least a portion of the third layer of the second multi-layer sheet such that a portion of the second layer of the second multi-layer sheet is exposed through the opening of the first layer of the second multi-layer sheet;
a separator disposed between the first layer of the first multi-layer sheet and the first layer of the second multi-layer sheet and covering the opening of the first layer of the first multi-layer sheet and the opening of the first layer of the second multi-layer sheet;
a first electrode material disposed between the separator and the exposed portion of the second layer of the first multi-layer sheet such that the second layer of the first multi-layer sheet is electrically connected to the first electrode; and
a second electrode material disposed between the separator and the exposed portion of the second layer of the second multi-layer sheet such that the second layer of the second multi-layer sheet is electrically connected to the second electrode material,
the first multi-layer sheet, the second multi-layer sheet, the separator, the first electrode material and the second electrode material collectively form an electrochemical cell.
20. The apparatus of claim 19 , wherein the second layer of the first multi-layer sheet includes a portion that extends outside an outer perimeter of the first layer of the first multi-layer sheet, the second layer of the second multi-layer sheet including a portion that extends outside an outer perimeter of the first layer of the second multi-layer sheet.
21. The apparatus of claim 19 , wherein the opening of the first layer of the first multi-layer sheet is a first opening, the portion of the second layer exposed through the first opening of the first layer the first multi-layer sheet is a first portion, the first layer defines a second opening, a second portion of the second layer is exposed through the second opening.
22. The apparatus of claim 19 , wherein the first multi-layer sheet defines an angled wall portion and a bottom surface integral with the angled bottom portion, the angled wall portion, bottoms surface and the first separator collectively defining a cavity, the first electrode material being disposed within the cavity.
23. The apparatus of claim 19 , wherein the first layer of the first multi-layer sheet and the first layer of the second multi-layer sheet are each formed with a cast polypropylene material.
24. The apparatus of claim 19 , wherein the conductive material of the second layer of the first multi-layer sheet includes an aluminum material, the conductive material of the second layer of the second multi-layer sheet includes a copper material.
25. The apparatus of claim 19 , wherein the electrochemical cell is a first electrochemical cell, the first electrochemical cell configured to be serially connected to a second electrochemical cell.
26. An apparatus, comprising:
a multi-layer sheet for encasing an electrode material of an electrochemical cell, the multi-layer sheet including
an outer layer;
an intermediate layer including a conductive substrate; and
an inner layer including a cast polypropylene material disposed on a portion of the conductive substrate, the intermediate layer being disposed between the outer layer and the inner layer,
the inner layer defining an opening through which a conductive region of the intermediate layer is exposed such that the electrode material can be electrically connected to the conductive region.
27. The apparatus of claim 26 , wherein the opening is a first opening, the conductive region is a first conductive region, the inner layer defining a second opening such that a second conductive region of the intermediate layer is exposed, the second conductive region being disposed at a non-zero distance from the first conductive region.
28. The apparatus of claim 26 , wherein the inner layer defines a plurality of openings including the opening, the plurality of openings exposing a plurality of conductive regions of the intermediate layer including the conductive region.
29. The apparatus of claim 26 , wherein the outer layer is a heat resistant film.
30. The apparatus of claim 26 , wherein the outer layer is a polyamide material.
31. The apparatus of claim 26 , wherein the conductive substrate includes at least one of aluminum and copper.
32. The apparatus of claim 26 , wherein the cast polypropylene material is thermally bondable to itself.