Chemistry: electrical current producing apparatus – product – and – Plural concentric or single coiled electrode
Patent
1995-10-06
1997-05-27
Maples, John S.
Chemistry: electrical current producing apparatus, product, and
Plural concentric or single coiled electrode
296233, 429127, 429162, H01M 610, H01M 646
Patent
active
056330979
DESCRIPTION:
BRIEF SUMMARY
The present invention relates to improved methods and materials for the manufacture of electrochemical cells, particularly but not exclusively for dry-cell batteries, and improved electrochemical cells provided thereby.
In the manufacture of conventional dry-cell batteries, the anode and cathode materials are applied to separate webs of insulating material which are then assembled together with electrolyte gel therebetween to form an electrolytic cell. Individual cells are then stacked together to form a battery. The required connections between adjacent anodes and adjacent cathodes (in a parallel-connected battery), or between the anodes and cathodes of successive cells (in a series-connected battery) must then be established by other means. The assembly of the cells and connection of the anodes and cathodes is inconvenient and time-consuming, requiring highly specialised plant if the process is to be automated.
It is an object of the present invention to provide improved methods and materials for the manufacture of electrochemical cells, whereby the manufacturing process is simplified and may be carried out by "standard" automated techniques.
In accordance with a first aspect of the invention there is provided a method of manufacturing electrochemical cells comprising the steps of applying layers of electrically conductive material, layers of cathode material and layers of anode material to first and second flexible, electrically insulating surfaces in respective predetermined patterns such that the areas of applied anode and cathode material corresponding to anodes and cathodes of individual cells on each of said surfaces are formed in electrical connection with or isolation from one another by said pattern of conductive material as required in the finished battery; and assembling said surfaces together such that respective areas of anode and cathode material on said first surface are aligned with corresponding areas of cathode and anode material of said second surface, electrolyte material being disposed between said first and second surfaces such that a plurality of electrically interconnected cells are formed thereby.
Preferably, said conductive material is applied to said surfaces prior to the application of said anode and cathode materials in patterns such that selected anodes and cathodes on each of said surfaces are electrically connected as required in the assembled battery.
Preferably also, a layer of insulating material is applied to at least one of said surfaces in a pattern such that said areas of anode and cathode materials remain exposed.
Preferably also, said layer of insulating material defines a plurality of wells surrounding said areas of anode and cathode material, said electrolyte material being applied to said surface so as to fill said wells prior to the assembly of the first and second surfaces.
Preferably also, said patterns of materials define at least one row of series connected cells extending in a first direction across said surfaces.
Preferably also, said patterns of materials define a plurality of rows of series connected cells extending in said first direction, and a plurality of columns of parallel connected cells extending in a second direction across said surfaces.
In one embodiment of the invention, said first and second surfaces are provided by first and second substrates. In this case, the assembled substrates are preferably folded at least once prior to final packaging to form a finished battery.
In a second embodiment of the invention, the respective surfaces to which the respective patterns of materials are applied are opposite surfaces of the same substrate, the cells being formed by rolling up the substrate so that areas of anode material on one side are aligned with areas of cathode material on the other side (and vice versa), with electrolyte therebetween.
In a first case, the substrate may be an elongate strip with continuous anodes and cathodes disposed side by side and extending along its length, such that a plurality of cells are formed connected in series
REFERENCES:
patent: 3006980 (1961-10-01), Story
patent: 3230115 (1966-01-01), Tamminen
patent: 3313657 (1967-04-01), Wood
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