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Abstract

An improved current collector for electrochemical cells is formed of a conductive porous foam. The foam is preferably a nickel foam as is often used as an electrochemical cell substrate. The high porosity foam's compressibility and resiliency provide an adaptive contact surface which accommodates variations in the shape and position of electrodes and other circuit elements. By using this material as an improved current collector, electrochemical cells are more easily produced with reduced internal resistance. Improved methods of assembly are a result of the nature of the high porosity foam material and its compliance. The foam collector may be used as a pressure connection or welded to the spiral edge of jelly-roll electrode assemblies. To increase effective contact area and also improve resistance to vibration forces, portions of the collector are compressed in a radial space between a jelly-roll assembly and the surrounding container. Foam current collectors according to the invention also have a low profile increasing the productive volume of the cell. The foam collector may be connected to the spiral edge of negative or positive electrodes of standard jelly-roll configuration cells. The advantages of reduced resistance is particularly beneficial to high drain rate cells such as nickel-metal hydride cells.

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First Claim