Polymer dipped pouch cell

Abstract

A pouch cell includes a copper foil forming a pouch, an active material layer adjacent to the copper foil inside the pouch forming a cathode with the copper, and a lithium-based anode inside the pouch. The cell includes a separator interposing the one active material layer and the lithium-based anode, and an electrolyte. In other embodiments, the active material forms an anode with the copper and the cathode is a lithium-based cathode.

1 . A method of forming a battery cell comprising:
 preparing a pouch made of copper foil, the copper foil being a unitary segment of copper foil having a folded edge forming a bottom of the pouch and equal-sized opposite halves of the pouch adjacent to the folded edge being sealed sides;   lining an interior portion of the pouch with an active material including an acidified metal oxide to create a cathode;   providing a lithium-based anode surrounded by a separator inside the pouch;   providing an electrolyte inside the pouch; and   sealing the pouch.   
     
     
         2 . The method of  claim 1 , further comprising adding an insulating layer outside the pouch including polyisobutylene. 
     
     
         3 . The method of  claim 1 , further comprising attaching a first terminal tab to the cathode inside the pouch and routing the first terminal tab to outside the pouch. 
     
     
         4 . The method of  claim 1 , further comprising attaching a second terminal tab to the lithium-based anode inside the pouch and routing the second terminal tab to outside the pouch. 
     
     
         5 . The method of  claim 1 , wherein the active material is applied in at least one layer inside the pouch with a density of about 6.49 mg/cm 2 . 
     
     
         6 . The method of  claim 1 , wherein the separator comprises a pouch containing the lithium-based anode. 
     
     
         7 . The method of  claim 1 , wherein the separator comprises polypropylene. 
     
     
         8 . The method of  claim 1 , wherein the lithium-based anode is a lithium foil. 
     
     
         9 . The method of  claim 1 , wherein the lithium-based anode consists of metallic lithium. 
     
     
         10 . The method of  claim 1 , further comprising providing the battery cell.