High durability lithium-ion cells

Abstract

A rechargeable battery and a method of fabricating which includes stacking a plurality of electrode pages having an uncoated portion between portions coated with an active electrode material. The electrode pages are arranged in a stack and an overall current collector is connected at the uncoated portion in order to form an electrode booklet. The overall current collector maintains the arrangement of the electrode pages and electrically connects all of the uncoated portions of the electrode pages. A tilted stack of electrode pages is utilized when a large number of electrodes are desired to result in a battery cell having a vertical orientation.

1 . An electrode booklet for a rechargeable battery, comprising
 a plurality of electrode pages, each electrode page being a foil having a shape symmetric about a center line and having a top and bottom surface coated with an active electrode material at similar portions other than a central uncoated portion which extends between edges of the foil and includes the center line, and   at least one overall current collector disposed along the uncoated portion of at least one of said plurality of electrode pages, said electrode pages being in a stack arrangement and similarly oriented, with said at least one overall current collector being connected to the uncoated portion of all of the plurality of electrode pages to maintain said plurality of electrode pages in the stack arrangement and to provide an electrical connection between all of the plurality of electrode pages.   
     
     
         2 . A stacked electrode assembly of a battery, comprising:
 an electrode booklet of  claim 1 , wherein the active electrode material is an active anode material to form an anode booklet,   an electrode booklet of  claim 1 , wherein the active electrode material is an active cathode material to form a cathode booklet, and   a separator material for separating the active anode material from the active cathode material,   said anode booklet and cathode booklet being substantially similar in size, shape and number of pages, and being in a folded condition about the uncoated portions,   said at least one overall current collectors being connected to the uncoated portion of each of said plurality of electrode pages in a manner to form a vertical stack of coated portions,   the booklets being arranged to alternate coated portions of said anode booklet with coated portions of said cathode booklet to result in a vertical stack with the separator material separating each coated portion, and   the at least one overall current collector of the anode booklet being disposed on one side of the resulting vertical stack and the at least one overall current collector of the cathode booklet being disposed on the opposite side of the resulting vertical stack.   
     
     
         3 . A stacked electrode assembly of a battery, comprising:
 an electrode booklet of  claim 1 , wherein the active electrode material is an active anode material to form an anode booklet,   an electrode booklet of  claim 1 , wherein the active electrode material is an active cathode material to form a cathode booklet, and   a separator material for separating the active anode material from the active cathode material,   said anode booklet and cathode booklet being substantially similar in size, shape and number of pages, and being in a folded condition about the uncoated portions,   said at least one overall current collectors being connected to the uncoated portion of each of said plurality of electrode pages in a manner to form a stack of coated portions being at a selected angle from vertical,   the booklets being arranged to alternate coated portions of said anode booklet with coated portions of said cathode booklet to result in a vertical stack with the separator material separating each coated portion, and   the at least one overall current collector of the anode booklet being disposed on one side of the resulting vertical stack and the at least one overall current collector of the cathode booklet being disposed on the opposite side of the resulting vertical stack.   
     
     
         4 . A stacked electrode assembly, comprising
 a semi anode booklet having a plurality of anode pages, each page having, at one end, an active anode material portion on the top and bottom surfaces thereof, an uncoated portion at the other end and at least one overall current collector disposed on the uncoated portion of at least one anode page and connecting the plurality of anode pages,   a semi cathode booklet having a plurality of cathode pages, each page having, at one end, an active cathode portion on the top and bottom surfaces thereof, an uncoated portion at the other end and at least one overall current collector disposed on the uncoated portion of at least one cathode page and connecting the plurality of cathode pages, and   a separator material for separating the active anode material from the active cathode material,   said active anode material and active cathode material being substantially similar in size and shape, and arranged to alternate active anode material with active cathode material in a manner to result in the coated portions being in a vertical stack with the separator material separating each coated portion,   the at least one overall current collector of the anode booklet being disposed on one side of the vertical stack and the at least one overall current collector of the cathode booklet being disposed on the opposite side of the vertical stack,   said uncoated portions of said anode pages being of a progressively increasing size from an anode page closest to its overall current collector to an anode page furthest from its overall current collector, and   said uncoated portions of said cathode pages being of a progressively increasing size from a cathode page closest to its overall current collector to a cathode page furthest from its overall current collector,   
     
     
         5 . The stacked electrode assembly of a battery of  claim 3 , wherein the selected angle is between 1 and 80 degrees. 
     
     
         6 . The stacked electrode assembly of a battery of  claim 2 ,  3  or  4 , wherein said separator material is in a continuous strip with a longitudinal edge of the strip being parallel to the center lines. 
     
     
         7 . The stacked electrode assembly of a battery of  claim 2 ,  3  or  4 , further comprising
 an insulating base for supporting the overall current collectors of the anode booklet and the cathode booklet. 
 
     
     
         8 . A multiple stacked electrode assembly of a battery, comprising
 a plurality of stacked electrode assemblies of  claim 2 ,  3  or  4  arranged with the overall current collectors of the anode booklets in vertical alignment and the overall current collectors of the cathode booklets in vertical alignment,   a main positive collecting plate electrically connecting the vertically aligned overall current collectors of the anode booklets,   a main negative collecting plate electrically connecting the vertically aligned overall current collectors of the cathode booklets, and   an insulating base for supporting the overall current collectors of the anode booklets and the cathode booklets.   
     
     
         9 . A rechargeable battery, comprising
 a battery can,   the stacked electrode assembly of  claim 7  disposed in the battery can, the insulating base being adjacent the bottom of the battery can,   a battery cap having current collecting posts, with the overall current collectors connected electrically to the current collecting posts, said battery cap being sealed to the battery can, and   an electrolyte filling the battery can.   
     
     
         10 . A rechargeable battery, comprising
 a battery can,   the stacked electrode assembly of  claim 8  disposed in the battery can, the insulating base being adjacent the bottom of the battery can,   a battery cap having current collecting posts, with the overall current collectors connected electrically to the current collecting posts, said battery cap being sealed to the battery can, and   an electrolyte filling the battery can.