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 laminate sheet for encasing an electrode material of an electrochemical cell, the multi-layer laminate sheet including
an outer layer;
an intermediate layer including a conductive substrate; and
an inner layer 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, copper, nickel, titanium, stainless steel, gold, platinum and carbon.
7. The apparatus of claim 1 , wherein the inner layer is formed with a material configured to be thermally bondable to itself.
8. The apparatus of claim 1 , wherein the inner layer includes a cast polyolefin material.
9. An apparatus, comprising:
a casing for an energy storage device, the casing including a conductive metallic sheet and a polymer coating disposed on at least a portion of a first surface of the conductive metallic sheet,
the polymer coating defining a plurality of openings,
the plurality of openings exposing a plurality of conductive regions of the conductive metallic sheet to allow electrical communication between an electrode material and the conductive metallic sheet so that the conductive metallic sheet functions as a current collector of the energy storage device.
10. The apparatus of claim 9 , further comprising:
an outer layer disposed on at least a portion of a second surface of the conductive metallic sheet configured to electrically insulate the conductive metallic sheet.
11. The apparatus of claim 9 , wherein the conductive metallic sheet is formed to define a cavity for receiving the electrode material.
12. The apparatus of claim 11 , wherein the plurality of openings are positioned in the cavity for contacting the electrode material.
13. The material of claim 12 , wherein the formed conductive metallic sheet is a first formed conductive metal sheet, the polymer coating is a first polymer coating and is configured to thermally bond with itself,
the first formed conductive metallic sheet has a contact region surrounding the cavity, the contact region having the polymer coating disposed thereon and configured to facilitate sealing the periphery of the cavity to a second polymer coating disposed on a second formed conductive metal sheet.
14. An apparatus, comprising:
a plurality of electrochemical cells each comprising a multi-layer laminate sheet for encasing an electrode material thereof, each multi-layer laminate sheet including
a first layer;
a second layer including a conductive substrate; and
a third layer disposed on a portion of the conductive substrate, the second layer being disposed between the first layer and the third layer, the third layer defining an opening through which a conductive region of the second layer is exposed.
15. The apparatus of claim 14 , wherein the electrochemical cells of the plurality of electrochemical cells are connected in series.
16. The apparatus of claim 15 , further comprising a housing, wherein the plurality of electrochemical cells is disposed within the housing.
17. The apparatus of claim 16 , further comprising an inert gas.
18. The apparatus of claim 16 , wherein the housing is hermetically sealed.
19. The apparatus of claim 14 , wherein the first layer is a laminate sheet that seals its respective one of the plurality of electrochemical cells.
20. The apparatus of claim 14 , further comprising an electrode material disposed in the opening defined by the third layer.
21. The apparatus of claim 14 , wherein the conductive substrate includes at least one of aluminum, copper, nickel, titanium, stainless steel, gold, platinum and carbon.