Chemistry: electrical current producing apparatus – product – and – Current producing cell – elements – subcombinations and... – Flat-type unit cell and specific unit cell components
Reexamination Certificate
1998-12-17
2001-05-29
Ryan, Patrick (Department: 1725)
Chemistry: electrical current producing apparatus, product, and
Current producing cell, elements, subcombinations and...
Flat-type unit cell and specific unit cell components
C429S206000, C429S233000, C429S235000, C429S243000, C029S002000
Reexamination Certificate
active
06238819
ABSTRACT:
FIELD OF THE INVENTION
The present invention relates to a metal foam support member, to an electrode made from the support member and methods of producing each, as well as relating to providing an integral connection tab member to the electrode. The electrode is useful as a battery electrode.
BACKGROUND OF THE INVENTION
Various means have been provided for supplying an electrode connection to a battery terminal. Where a fiber structure electrode framework of metallized plastic fibers is provided, it has been taught, as in U.S. Pat. No. 4,755,441, to weld a current-conducting lug to a reinforced edge of the electrode framework. The current-conducting lug is provided with a stepped area to which the welded connection is made.
U.S. Pat. No. 5,558,681 discloses a method of bonding a metal connection to an electrode having a foam support structure, including a main core and a retaining core. A metal strip is affixed to the support by welding under compression. The strip may be welded along the edge of a retaining core which has been previously disposed to the main core, or the strip can be positioned between the main core and the retaining core.
A connection tab may be made from a single piece of metal foam, as is taught in U.S. Pat. No. 5,578,397 which describes a method of forming an electrode plate and plate head which includes a connection tab. Such connection tab is formed by compressing the support in two directions, resulting in a connection tab having a density of 2.5 times the density of the metal foam support.
It has also been taught to install a connection tab by removing sections of active material where such tabs are to be located and then attaching a thin strip of material such as by spot welding. Thus, U.S. Pat. No. 5,549,717 describes an electrode provided with an electrical lead or tab which has been welded on the outer surface of the electrode in such a manner that the outer surface of the tab is substantially flush with the outer surface of the electrode.
It would, nevertheless, be desirable to provide a foam substrate connection zone which could provide an integral bus to which a connection tab could be secured. It would also be advantageous to provide increased electrical conductivity of an electrode formed from the foam substrate with such connection tab.
SUMMARY OF THE INVENTION
There has now been provided a metal foam support for use in battery applications, which support utilizes an integral bus for securing a connection tab. This can be obtained together with improved securing characteristics, such as improved welding characteristics, and increased electrical conductivity, as in the welded area.
In one aspect, the invention is directed to a metal foam support member in sheet form having. length in the longitudinal direction, width in the transverse direction, thickness in the direction between front and back major faces of said sheet form support member, and first and second long, outer edges in said longitudinal direction positioned at least substantially parallel to one another, which metal foam support member comprises at least substantially one layer of metal foam and has at least one outer edge that is a stacked edge of a plurality of at least two layers of metal foam including at least one layer of said metal foam support member, and with at least one layer of said stacked edge that is a layer situated on a support member major face.
In another aspect, the invention is directed to an electrode comprising a layer of a metal foam support member in sheet form containing an active filling, said metal foam support member having length in the longitudinal direction, width in the transverse direction, thickness in the direction between front and back major faces of said sheet form support member, and first and second long outer edges in said longitudinal direction positioned at least substantially parallel to one another, which metal foam support member comprises at least substantially one layer of metal foam and has at least one outer edge that is a stacked edge of a plurality of at least two layers of metal foam including at least one layer of said metal foam support member, and with at least one layer of said stacked edge that is a layer situated on a support member major face.
In yet another aspect, the invention is directed to a method of producing an electrode comprising a layer of a metal foam support member containing an active filling, said metal foam support member having a length in the longitudinal direction, a width in the transverse direction, front and back major faces, and first and second long, outer edges in said longitudinal direction positioned at least substantially parallel to one another, with at least one outer edge that is a stacked edge of a plurality of at least two layers of metal foam including at least one layer of said metal foam support member, and with at least one edge layer that is situated on a support member face, which method comprises the steps of:
(1) providing a metal foam support member in sheet form as a layer of said metal foam;
(2) establishing at least one of said support member outer edges as a stacked edge comprising at least two metal foam layers, with at least one layer on a major face of said support member;
(3) compressing said stacked edge;
(4) introducing active filling material into said sheet form electrode support member; and
(5) cutting said filled support member to provide said electrode as a segment of said filled support member having a compressed stacked edge.
In yet another aspect, the invention is directed to an electrode assembly comprising an electrode having a thin layer of a metal foam support member in sheet form containing an active filling, said metal foam support member having length in the longitudinal direction, width in the transverse direction, thickness in the direction between front and back major faces of said sheet form support member, and first and second long, outer edges in said longitudinal direction positioned at least substantially parallel to one another, which metal foam support member comprises at least substantially one layer of metal foam and has at least one outer edge that is a stacked edge of a plurality of at least two layers of said metal foam support member, and with at least one layer of said stacked edge that is a layer situated on a support member major face, said electrode being spirally wound around a geometric axis.
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Cahill Michael F.
Shaw Greg S.
Hudak & Shunk Co. L.P.A.
Pittman Zidia T.
Ryan Patrick
Stork, N.V.
Tyrpak Michele M.
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