US 12,255,337 B2
Electrochemical cell with integrated ceramic separator
Adrian Yao, Phoenix, AZ (US); Jonathan Hwang, Phoenix, AZ (US); and Mayuresh Keskar, Scottsdale, AZ (US)
Assigned to EnPower, Inc., Indianapolis, IN (US)
Filed by EnPower, Inc., Indianapolis, IN (US)
Filed on Aug. 20, 2020, as Appl. No. 16/998,626.
Application 16/998,626 is a division of application No. 16/727,787, filed on Dec. 26, 2019, granted, now 10,998,553.
Claims priority of provisional application 62/928,975, filed on Oct. 31, 2019.
Prior Publication US 2021/0135237 A1, May 6, 2021
Int. Cl. H01M 50/431 (2021.01); H01M 4/66 (2006.01); H01M 50/411 (2021.01); H01M 50/44 (2021.01); H01M 50/46 (2021.01); H01M 4/02 (2006.01)
CPC H01M 4/664 (2013.01) [H01M 50/411 (2021.01); H01M 50/431 (2021.01); H01M 50/44 (2021.01); H01M 50/46 (2021.01); H01M 2004/027 (2013.01); H01M 2004/028 (2013.01)] 4 Claims
OG exemplary drawing
 
1. An electrochemical cell comprising:
a first electrode including:
a first current collector substrate, and
a first active material layer disposed on the first current collector substrate, the first active material layer comprising a plurality of first active material particles; and
a second electrode including:
a second current collector substrate, and
a second active material layer disposed on the second current collector substrate, the second active material layer comprising a plurality of second active material particles;
an integrated separator layer disposed adjacent to and directly contacting the first active material layer and the second active material layer, the integrated separator layer comprising a plurality of ceramic particles;
a first interlocking region disposed between and coupling the first active material layer to the integrated separator layer, wherein the first interlocking region comprises a non-planar interpenetration of first fingers of the first active material layer and second fingers of the integrated separator layer; and
a second interlocking region disposed between and coupling the second active material layer to the integrated separator layer, wherein the second interlocking region comprises a non-planar interpenetration of third fingers of the second active material layer and fourth fingers of the integrated separator layer;
wherein a thickness of the first interlocking region is greater than an average length of the second fingers; and
wherein a thickness of the second interlocking region is greater than an average length of the fourth fingers.