US 12,087,904 B2
Electrochemical cell having thin metal foil packaging and a method for making same
Glenn Amatucci, Peapack, NJ (US); Irene Plitz, Toms River, NJ (US); Linda Sung, Morris Plains, NJ (US); and Anthony Ferrer, Red Lion, NJ (US)
Assigned to Rutgers, The State University of New Jersey, New Brunswick, NJ (US)
Filed by Rutgers, The State University of New Jersey, New Brunswick, NJ (US)
Filed on Mar. 23, 2023, as Appl. No. 18/125,550.
Application 18/125,550 is a continuation of application No. 15/769,270, previously published as PCT/US2016/059071, filed on Oct. 27, 2016.
Claims priority of provisional application 62/249,590, filed on Nov. 2, 2015.
Prior Publication US 2023/0231178 A1, Jul. 20, 2023
Int. Cl. H01M 10/0525 (2010.01); H01M 4/133 (2010.01); H01M 4/38 (2006.01); H01M 4/66 (2006.01); H01M 10/058 (2010.01); H01M 10/0585 (2010.01); H01M 50/105 (2021.01); H01M 50/119 (2021.01); H01M 50/133 (2021.01); H01M 50/545 (2021.01)
CPC H01M 10/0525 (2013.01) [H01M 4/133 (2013.01); H01M 4/38 (2013.01); H01M 4/661 (2013.01); H01M 10/058 (2013.01); H01M 50/105 (2021.01); H01M 50/119 (2021.01); H01M 50/133 (2021.01); H01M 50/545 (2021.01); H01M 10/0585 (2013.01); H01M 2220/20 (2013.01); Y02E 60/10 (2013.01); Y02P 70/50 (2015.11)] 14 Claims
OG exemplary drawing
 
1. A method comprising:
providing a metal foil packaging comprising at least one sheet of metal foil;
bonding the metal foil packaging to an electrochemical cell stack,
wherein the metal foil packaging has a perimeter extending around at least a portion of the electrochemical cell stack;
wherein an electrode tab extends from the electrochemical stack through the metal foil packaging;
laser welding the metal foil packaging to form a metal-to-metal welded seal,
wherein the laser welding occurs at a speed of at least 0.1 m/s,
wherein the metal-to-metal seal is less than 1 mm away from the electrochemical cell stack,
using a sealant, heat sealing the electrode tab to the metal foil packaging such that:
the electrode tab is electrically insulated from the metal foil packaging, and
the thin metal foil packaging is hermetically sealed against an external environment to form an electrochemical cell.