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WO2000036668A1 - Dispositifs d'etancheite equipant des elements d'accumulateur metal-air et destines a empecher une fuite d'electrolyte - Google Patents

Dispositifs d'etancheite equipant des elements d'accumulateur metal-air et destines a empecher une fuite d'electrolyte Download PDF

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Publication number
WO2000036668A1
WO2000036668A1 PCT/US1999/028421 US9928421W WO0036668A1 WO 2000036668 A1 WO2000036668 A1 WO 2000036668A1 US 9928421 W US9928421 W US 9928421W WO 0036668 A1 WO0036668 A1 WO 0036668A1
Authority
WO
WIPO (PCT)
Prior art keywords
casing
sealing element
casing elements
elements
protrusion
Prior art date
Application number
PCT/US1999/028421
Other languages
English (en)
Inventor
Yaron Shrim
Mariano Abramson
Robert B. Dopp
Original Assignee
Electric Fuel Limited
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Electric Fuel Limited filed Critical Electric Fuel Limited
Priority to AU32064/00A priority Critical patent/AU3206400A/en
Publication of WO2000036668A1 publication Critical patent/WO2000036668A1/fr

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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/10—Primary casings; Jackets or wrappings
    • H01M50/102—Primary casings; Jackets or wrappings characterised by their shape or physical structure
    • H01M50/103—Primary casings; Jackets or wrappings characterised by their shape or physical structure prismatic or rectangular
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/06—Electrodes for primary cells
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M12/00—Hybrid cells; Manufacture thereof
    • H01M12/04—Hybrid cells; Manufacture thereof composed of a half-cell of the fuel-cell type and of a half-cell of the primary-cell type
    • H01M12/06—Hybrid cells; Manufacture thereof composed of a half-cell of the fuel-cell type and of a half-cell of the primary-cell type with one metallic and one gaseous electrode
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/62—Selection of inactive substances as ingredients for active masses, e.g. binders, fillers
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/62—Selection of inactive substances as ingredients for active masses, e.g. binders, fillers
    • H01M4/628—Inhibitors, e.g. gassing inhibitors, corrosion inhibitors
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/64—Carriers or collectors
    • H01M4/70—Carriers or collectors characterised by shape or form
    • H01M4/72—Grids
    • H01M4/74—Meshes or woven material; Expanded metal
    • H01M4/745—Expanded metal
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/86—Inert electrodes with catalytic activity, e.g. for fuel cells
    • H01M4/8605—Porous electrodes
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/86—Inert electrodes with catalytic activity, e.g. for fuel cells
    • H01M4/96—Carbon-based electrodes
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/10—Primary casings; Jackets or wrappings
    • H01M50/102—Primary casings; Jackets or wrappings characterised by their shape or physical structure
    • H01M50/109—Primary casings; Jackets or wrappings characterised by their shape or physical structure of button or coin shape
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/10—Primary casings; Jackets or wrappings
    • H01M50/138—Primary casings; Jackets or wrappings adapted for specific cells, e.g. electrochemical cells operating at high temperature
    • H01M50/1385—Hybrid cells
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/10—Primary casings; Jackets or wrappings
    • H01M50/183—Sealing members
    • H01M50/186—Sealing members characterised by the disposition of the sealing members
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M6/00—Primary cells; Manufacture thereof
    • H01M6/50—Methods or arrangements for servicing or maintenance, e.g. for maintaining operating temperature
    • H01M6/5033—Methods or arrangements for servicing or maintenance, e.g. for maintaining operating temperature used as charging means for another battery
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M8/00—Fuel cells; Manufacture thereof
    • H01M8/02—Details
    • H01M8/0202—Collectors; Separators, e.g. bipolar separators; Interconnectors
    • H01M8/0204—Non-porous and characterised by the material
    • H01M8/0223—Composites
    • H01M8/0228—Composites in the form of layered or coated products
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/42—Methods or arrangements for servicing or maintenance of secondary cells or secondary half-cells
    • H01M10/44—Methods for charging or discharging
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M16/00—Structural combinations of different types of electrochemical generators
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M2004/021—Physical characteristics, e.g. porosity, surface area
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/86—Inert electrodes with catalytic activity, e.g. for fuel cells
    • H01M2004/8678—Inert electrodes with catalytic activity, e.g. for fuel cells characterised by the polarity
    • H01M2004/8689—Positive electrodes
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/62—Selection of inactive substances as ingredients for active masses, e.g. binders, fillers
    • H01M4/621—Binders
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/86—Inert electrodes with catalytic activity, e.g. for fuel cells
    • H01M4/90—Selection of catalytic material
    • H01M4/9016—Oxides, hydroxides or oxygenated metallic salts
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M6/00—Primary cells; Manufacture thereof
    • H01M6/42—Grouping of primary cells into batteries
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M8/00—Fuel cells; Manufacture thereof
    • H01M8/02—Details
    • H01M8/0202—Collectors; Separators, e.g. bipolar separators; Interconnectors
    • H01M8/0204—Non-porous and characterised by the material
    • H01M8/0206—Metals or alloys
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M8/00—Fuel cells; Manufacture thereof
    • H01M8/02—Details
    • H01M8/0202—Collectors; Separators, e.g. bipolar separators; Interconnectors
    • H01M8/0204—Non-porous and characterised by the material
    • H01M8/0213—Gas-impermeable carbon-containing materials
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M8/00—Fuel cells; Manufacture thereof
    • H01M8/04—Auxiliary arrangements, e.g. for control of pressure or for circulation of fluids
    • H01M8/04082—Arrangements for control of reactant parameters, e.g. pressure or concentration
    • H01M8/04089—Arrangements for control of reactant parameters, e.g. pressure or concentration of gaseous reactants
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/10—Energy storage using batteries
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/30—Hydrogen technology
    • Y02E60/50—Fuel cells

Definitions

  • the present invention relates to sealing features in metal-air battery cells for the prevention of electrolyte leakage.
  • the invention relates to a resilient and compressible seal disposed between two casing elements of a battery cell.
  • the seal can also take the form of an insulated, liquid having a relatively high viscosity, such as tar.
  • the invention also relates to a seal made of layer of generally uncompressed Teflon® with compressed portions. The compressed portions provide the sealing function. The seal prevents electrolyte from escaping the confines of the battery casing through gaps between the casing elements or through openings formed on either of the casing elements.
  • the container Since many electronic devices are designed to house a battery that is substantially rectangular in shape, prism-shaped cells are particularly suited to powering these devices. Further, to reduce the weight of the battery cells, it is preferable for the container to be made of a thin, light material. In many battery cells, the container makes up a large fraction of the weight of the cell. The need to minimize the thickness of the material must be balanced against the need for strength since electrochemical cells can place severe demands on cell housing designs.
  • the present invention relates to prism-shaped battery cells having casings that are at least partly made of metal or a material that is deformable as metal.
  • the benefits of using a metal casing include the use of the casing as integral electrodes as well as the many well- known cost, manufacturability, strength, and precision features that metal provides.
  • external and internal force can generate tremendous loads that must be resisted or compensated.
  • the oxidation of the zinc anode to generate current causes the anode to expand considerably. Volume increases of up to 60% have been reported.
  • Hydrogen may be produced by the parasitic reaction of zinc with the cell's alkaline electrolyte. Hydrogen is even produced when the battery cell is dormant.
  • the built-up hydrogen may further increase the internal pressure of the battery cell. Increased internal pressure can compromise the mechanical integrity of the cell's casing, causing it to leak electrolyte, short circuit, and, potentially, even explode.
  • a known metal casing design e.g., button cells
  • the grommet prevents the casing elements from contacting each other and also effectively seals electrolyte in one portion of the cell from other parts of the cell.
  • the casing becomes deformed, the dimensions of the gap occupied by the grommet may change, and electrolyte may work its way around the grommet and leak through that gap. Further, the raised internal pressure of the casing can force electrolyte out through the gap.
  • metal-air battery cells the surfaces of the battery cells have small air access holes to permit the exchange of gases.
  • ambient oxygen reacts with the metal anode to generate current.
  • the holes are the means through which ambient oxygen can enter the battery cells.
  • One of the risks of having holes in the cells is the possibility that electrolyte will leak out of the battery cell through the same holes. Further, the risk is exacerbated by the possibly raised internal pressure of the casing.
  • Casing deformation causes electrical shorts when the metal casing elements contact each other or when opposite-polarity electrode materials inside the cell come into contact. Casing deformation can also cause the battery cell to lose electrical contact with the electronic device. A change in the dimensions of the battery cell can cause the electrodes to separate from the electrical contacts of the electronic device.
  • button-shaped battery cells are intrinsically strong and are commonly used to power watches, hearing aids, etc. Forces applied to the major surfaces of a button cell are resisted by the inherent strength of the cylindrical structure.
  • a button cell 10 has an internal pressure that is greater than ambient pressure.
  • the button cell 10 has two major casing elements 12, 14 that are engaged to form a button-shaped enclosure.
  • a peripheral bend portion 16 which shapes the outer casing element 12 over the inner casing element, prevents the two casing elements 12, 14 from separating.
  • An internal pressure which is represented by a force F Officer pushes the two casing elements 12, 14 in a direction of separation from each other. This separation force F, is resisted by a force F 2 , which is the force that the bend portion 16 exerts on the separating casing elements 12, 14.
  • a button cell 20 has two casing elements engaged to each other.
  • the inner and outer casing elements each have a side wall 22, 24, respectively, with a grommet 26 positioned therebetween.
  • the diameters of the side walls 22, 24 may change.
  • the diameter of the internal side wall 22 changes due to the force of the internal pressure
  • the diameter of the external side wall 24 changes due to the force exerted by the internal side wall 22 via the grommet 26.
  • the grommet 26 adequately seals the casing elements together.
  • the stress and strain of the side walls 22, 24 are relatively uniform around the circumference of the casing elements, with the side walls 22, 24 efficiently resisting the strain induced by the internal pressure.
  • a rectangular, prism-shaped cell 30 also has two casing elements with the inner casing element having four side walls 32 and the outer casing element having four side walls 34 and a grommet 36 positioned between the side walls 32, 34.
  • the side walls 32, 34 tend to distort because they lack the inherent strength that a cylindrical shape has to resist deformation. Due to the inherent characteristics of a prism- shaped cell 30, the side walls 32, 34 do not maintain their shape.
  • a prism-shaped cell In a prism-shaped cell, casing deformation can present serious problems. Unlike button-shaped battery cells, the forces due to increased internal pressure are not distributed uniformly around the perimeter of the cell of a prism-shaped cell, nor can the forces be adequately resisted by hoop strength.
  • a prism-shaped cell normally has long spans running from corner to corner. The long spanning wall portions of such a prism-shaped cell are inherently weak and susceptible to deformation.
  • a metal-air button cell 40 has two interfacing, inter- engaging casing elements 42, 52.
  • the cathode and anode casing elements 42, 52 are shaped to each have a substantially cylindrical-shaped side wall 46, 56, a major wall structure or base 48, 58, a peripheral corner 50, 60 positioned between the wall 46, 56 and the base 48, 58, and a peripheral edge 44, 54 forming an opening of the casing element 42, 52, respectively.
  • These casing elements 42, 52 are assembled so that the bases 48, 58 form two oppositely positioned and oppositely charged surfaces of the battery cell 40.
  • a grommet 62 positioned between the side walls 46, 56 electrically insulate and seal the casing elements 42, 52, and an approximately 45 degree bend 43 of the cathode casing element 42 prevents the casing elements 42, 52 from disengaging.
  • the prior art example also illustrates the peripheral edge 54 of the anode casing element 40 as being sharp, which often results from a shearing operation in the manufacturing process.
  • This sharp edge 54 can dig into and damage the grommet 62, causing electrolyte leakage and possibly a short circuit. Further, this sharp edge 54 can also bring about an undesired chemical reaction.
  • the casing element in a zinc-air battery cell, can be made of a nickel-stainless steel-copper triclad with a coating or film separating these metals from the zinc anode. All three of the tri-clad metals, if exposed to the zinc anode, can chemically react, resulting in the production of hydrogen or the introduction of contaminate ions into the electrolyte. The coating or film inhibits this reaction.
  • the shearing operation of the manufacturing process can expose the underlying nickel, increasing the rate of the reaction.
  • Fig. 4 also illustrates the side walls 46, 56 of the casing elements 42, 52 as being relatively perpendicular to the major surfaces 48, 58. In other words, the side walls 46, 56 are parallel.
  • One problem with this configuration relates to the assembly of the battery cell 40. Since the internal components are placed on the bottom (near the base 48) of the cathode casing element 42, the components must work its way down the entire height of the side wall 46. Dimensional tolerances in the components of the casing element 15 may cause the components to get stuck or become distorted as they move to their ultimate location.
  • Fig. 4 also illustrates the placement of the grommet 56 between the relatively smooth surfaces of the casing elements 42, 52.
  • electrolyte e.g. KOH
  • many different types of electrolyte e.g. KOH
  • Scratches on the surfaces of the casing elements 42, 52 can act as channels through which electrolyte can migrate and eventually leak out of the battery cell 40. Electrolyte leakage can cause the battery cell 40 to short circuit or even explode.
  • United States patent 5,537,733 describes a method for manufacturing a rectangular nickel-metal hydride secondary cell
  • U.S. patent 5,556,722 describes a prism-shaped casing for a lithium ion-type cell.
  • a grommet is disposed at least partly between two casing elements, which form the casing of the battery cell.
  • the grommet is shaped so that the when it is compressed by the casing elements, the grommet exerts a concentrated force against the casing elements at a small portion of the contact area of the grommet and casing elements. In this way, the area where the concentrated force is applied acts as the main barrier against electrolyte leakage.
  • a concentrated force can be applied by shaping the surface of the grommet to have small ridges or protrusion that exert the concentrated force around the gap between the casing element.
  • the concentrated force can also be applied by forming ridges or protrusions on the surface of the casing elements that contact the grommet.
  • a sticky, gel or liquid like sealant can be applied to fill gaps between the casing elements and the grommet.
  • the protrusions have a relatively small surface area compared to the total surface of the grommet. Because of this, the protrusions are more likely to experience greater stress than other portions of the grommet. This greater stress results in greater deformation, which further improves the seal of the battery cell.
  • the protrusions deform to take the shape of the casing elements. If the surface of the casing elements are not smooth, become corrugated by crimping or are scratched, the high stress on the protrusions causes the protrusions to conform plastically to the shape of the casing element surface and thus, improve the seal of the battery cell.
  • the battery cell can also be sealed without a grommet. Applying a sticky, gel or liquid- like sealant between the casing elements may prevent the leakage of electrolyte out of the battery cell.
  • a liquid with a relatively high viscosity, such as tar, can provide sufficient sealing properties that a grommet may not be necessary.
  • the invention also provides for a diaper ring between the casing elements to absorb any electrolyte that may have worked its way pass the grommet.
  • the diaper ring prevents electrolyte from leaking out of the battery cell and onto a person's hands or onto electronic components attached to the battery cell.
  • the diaper ring absorbs the electrolyte and is preferably insulated from at least one of the casing elements to prevent an electrical short.
  • the invention also provides sealing functions through a Teflon® seal formed around openings on one of the casing elements.
  • a generally planar layer of compressed Teflon and a generally planar layer of uncompressed Teflon is placed against or attached to a relatively flat air cathode with the layers of uncompressed Teflon and the air cathode sandwiching the layer of compressed Teflon.
  • the layer of uncompressed Teflon is directly or indirectly pressed against the casing element, thereby compressing areas of the uncompressed Teflon where the Teflon contacts the casing element.
  • the compressed areas of the uncompressed layer of Teflon® forms a seal that prevents the leakage of electrolyte out of the battery cell.
  • Teflon is preferable, due to its air permeability qualities.
  • the layer of uncompressed Teflon permits oxygen to pass through the layer and reach the air cathode while preventing electrolyte from bypassing the seal formed by the compressed portions.
  • the invention relates to a metal prism-shaped casing with features that make the casing strong, unlikely to deform, and leak electrolyte leakage.
  • the present invention also provides features that make the battery cell more reliable, inexpensive and mass- manufactureable. Ridges on the interior and exterior of the flat surfaces of the battery cell are formed to add strength to the casing. These ridges eliminate or reduce the tendency of the battery cells to bulge due to an increase in the internal pressure of the cell.
  • the side walls of the casing elements flare outwards from the flat surface to prevent the walls from collapsing inwardly and to make the battery cell easy to assemble.
  • the side walls are also shaped to provide for a better seal between the casing elements, thus preventing electrolyte from leaking.
  • the grommet also serves to separate and insulate the two casing elements. Further, a diaper ring placed between the casing elements absorbs electrolyte that may have worked its way past the grommet.
  • the casing element has a well or catch basin to catch adhesive or electrolyte that has managed to work its way past the separator.
  • the basin also provides an inexpensive means for ensuring that the air cathode remains electrically connected to the cathode casing element.
  • the basin eliminates the need to manufacture a casing element with sharp interior corners.
  • the shape of the basin further strengthens the casing elements.
  • the invention is not limited to battery cells having rectangular casings. Instead, the invention covers all prism-shaped battery cells, including but not limited to hexagonal, octagonal, and other cells having casings with relatively straight side walls.
  • Fig. 1 shows a cross-section representation of a button-shaped battery cell with vectors representing some of the forces that are present when the internal pressure is greater than ambient.
  • Fig. 2 shows a different cross-section representation of a button-shaped battery cell.
  • Fig. 3 shows a cross-section representation of a prism shaped battery cell with an internal pressure that is greater than ambient.
  • Fig. 4 shows a cross-section representation of a prior art example of a button-shaped metal-air battery cell.
  • Fig. 5 shows an enlarged, partial cross-section representation of the embodiment of Fig. 4.
  • Fig. 6 shows a cross-section representation of the embodiment of Fig. 4 with collapsing side walls.
  • Fig. 7 shows a partial cross-section representation of one example of the prior art.
  • Fig. 8 A shows a cross-section representation of a prism-shaped battery cell according to one embodiment of the invention.
  • Fig. 8B shows a different cross-section representation of the embodiment of Fig. 8 A.
  • Fig 9 shows a cross-section representation of an uncrimped cathode casing element of one embodiment of the invention
  • Fig. 10 shows a perspective view of the uncrimped cathode casing element of Fig. 9
  • Fig. 11 shows a perspective view of a cut-out portion of a cathode casing element under a bending moment.
  • Fig. 12A shows a perspective view of an uncrimped cathode casing element according to an alternative embodiment of the invention.
  • the casing element has notches at the rounded corners.
  • Fig. 12B shows a perspective view of another uncrimped cathode casing element according to an alternative embodiment of the invention.
  • Fig. 12C shows a cross-section representation of an assembled battery cell according to an alternative embodiment of the invention.
  • Figs. 12D(1) and 12D(2) shows two enlarged partial cross-section representations of a single embodiment according to the invention.
  • Fig 13 shows a cross-section representation of an anode casing element of the embodiment of Fig. 8.
  • Figs. 14 - 18 show enlarged partial cross-sectional representations of edges of an anode casing element according to alternative embodiments of the invention.
  • Figs. 19 - 21 show cross-section representations of ridges or ripples on a base of a casing element according to alternative embodiments of the invention.
  • Fig. 22 shows a perspective view of an anode casing element having ridges attached to its interior surface, according to an alternative embodiment of the invention.
  • Fig. 22 A shows a perspective view of a Teflon ® ring for incorporation into an embodiment of the invention
  • Fig. 23 shows an enlarged partial cross-section representation of a peripheral rim of the cathode casing element crimped around a peripheral rim of the anode casing element with vectors representing interacting forces, thereof.
  • Fig. 24 shows a force vector representation of the peripheral rim of Fig. 23.
  • Figs. 25A - 25B show partial cross-section representations of a single embodiment. The figures demonstrate the need for an engagement bend of an outer casing element to conform to shape of the inner casing element.
  • Fig. 26 shows a cross-section representation of an alternative embodiment of the invention.
  • the embodiment has a double bend to reduce the effects of "spring back.”
  • Figs. 26A - 26B show enlarged partial cross-section representations of the embodiment of Fig. 26, according to an alternative embodiment of the invention.
  • Fig. 27 shows a partial cross-section representation of another alternative embodiment of the invention.
  • Figs. 28 - 29 show two partial cross-section representations of two alternative embodiments of the invention. The embodiments are designed to increase stresses in certain areas to limit electrolyte leakage.
  • Figs. 30A and 30B show two enlarged cross-section representations of the embodiment of Fig. 8.
  • Fig. 30C shows a cross-section representation of an air cathode according to one embodiment of the invention.
  • Fig. 31 shows a cross-section representation of an air cathode according to an alternative embodiment of the invention.
  • Fig. 31 shows a perspective view of an air cathode with an embedded current collector, according to an alternative embodiment of the invention.
  • Fig. 32 shows a cross-section representation an not yet crimped cathode casing element with internal components.
  • the area dimensions of the internal components are sized to be slightly larger than the area dimensions that they are designed to occupy.
  • This embodiment is an alternative embodiment of the invention.
  • Fig. 33 shows a partial cross-section representation of the embodiment of Fig. 32 after assembly.
  • Fig. 34 shows a cross-section representation of an alternative embodiment of the invention.
  • the embodiment utilizes a snap-fitting strap to ensure that the casing elements remain engaged.
  • Figs. 35 - 38 show partial and full cross-section representations of an alternative embodiment of the invention.
  • the embodiment utilizes two cathodes to generate current.
  • Fig. 39 shows a cross-section representation of an embodiment similar to the embodiment of Figs. 35 - 38 according to the invention.
  • Figs. 8 A and 8B show an assembled prism-shaped metal-air battery cell 100 having two major casing elements, an anode casing element 102 and a cathode casing element 104.
  • the casing elements 102, 104 are substantially rectangular tray-shaped casing elements with a respective major wall structure or base 110, 112, continuous side walls 114, 116 meeting at corners 106, 108, a bend portion between the base 110, 112 and the side walls 114, 116, and a peripheral edge 118, 120.
  • the bend portion of the anode casing element 102 is a peripheral trough 142 and a peripheral rim 140
  • the bend portion of the cathode casing element 104 is a peripheral ledge 132 and a peripheral basin 134.
  • the internal components of the cell 100 including a metal anode 122, an air cathode 124, a separator 126 and a diffuser 128.
  • An insulated grommet 130 separates the side walls 114, 116 of the casing elements 102, 104 and prevents the casing elements 102, 104 from contacting each other.
  • the grommet 130 also protects the air cathode 124 from the anode casing element 102 and seals the casing elements 102, 104 together.
  • An anode current collector (not shown) electrically connects the metal anode 122 to the anode casing element 102, and a cathode current collector (not shown) electrically connects the air cathode 124 to the cathode casing element 104.
  • the casing elements 102, 104 are mutually engaged to each other and remain engaged by bending the side walls 116 of the cathode casing element 104 partially around the anode casing element 102, preferably by a crimping process.
  • the assembly process creates a compressive stress in the grommet 130 and the casing elements 102, 104, which seals the battery cell 100.
  • the stress is primarily derived from forces in the axial direction due to the shape of the casing elements 102, 104 during and after the assembly process is complete. This stress persists, at least partially, after the assembly process so that a seal is effectuated.
  • the air cathode 124 may contain a layer or two of uncompressed Teflon® which further seals the air cathode 124 to the cathode casing element 104.
  • the cathode casing element 104 of the battery cell 100 contains features that increase its strength and improve the reliability and manufacturability of the battery cell 100.
  • the peripheral ledge 132 and the peripheral basin 134 increase the strength and rigidity of the casing element 104 and also provide reliability benefits described hereinafter.
  • the ledge 132 and the basin 134 increase the strength and rigidity of the cathode casing element 104 by translating a portion of a load to the much stronger, rounded corners 108. This load can be due to external forces or resistance to internal pressure.
  • basin 134 helps to prevent collapse illustrated in Fig. 6, for example.
  • Fig. 6 For example, referring now to Fig.
  • FIG. 11 showing a perspective view of a cut out portion of the casing element 104, a bending moment - as would be generated by a force F applied to the center of the span and resisted by fixed support points S - is resisted by the curves of the ledge 132 and the basin 134.
  • the ledge 132 and the basin 134 translates a concentrated force applied in one area of the casing element 104 by spreading the force more evenly around the ledge 132 and the basin 134 areas, including areas near the corners 108.
  • the casing element 104 subjected to a load along one of its long spanning walls, is able to resist deformation by transferring part of the load to the rounded corners 108.
  • the side walls 116 of the "uncrimped" cathode casing element 104 widens from the peripheral basin 134 to the edge 120.
  • This outward flare may assist with the manufacture of the metal-air battery 100 by making it easier for the manufacturer to place the internal components into the cathode casing element 104.
  • the flare helps guide the components during assembly and permits full insertion of the parts without distortion of those parts. This feature is particularly advantageous when inserting the an air cathode 124 since the air cathode can be very delicate.
  • the internal components of the battery cell 100 should be able to easily slide into the cathode casing element 104.
  • the crimping or bending process may, although not necessarily, eliminate the flare, making the side walls 116 substantially perpendicular to the major surface 112 and the peripheral ledge 132.
  • assembling the battery cell 100 requires the manufacturer to bend or crimp the cathode casing element 104 at least partly around the anode casing element 102.
  • bending the edge 120 around the corners 106 of the anode casing element 102 may cause portions of the cathode casing element 104 to corrugate which may result in a poor electrolyte seal.
  • the cathode casing element 104 can be made of a very soft or annealed metal at the portions that are prone to corrugation. In some instances a small degree of corrugation may be acceptable.
  • notches 136 are cut near the corners 108 of the cathode casing element 104 to reduce the amount of excess material when the edge 120 is bent. Excess material can corrugate and compromise the seal. In addition, if the excess material is compressed to its elastic phase, it can elongate and form an electrical bridge to the anode casing element 102, causing the battery cell 100 to short circuit. The notches 136 solve this problem by reducing the amount of excess material.
  • Fig. 12B in another alternative embodiment, reduction of excess material to prevent corrugation and short circuiting can be accomplished by forcing the basin 134 downwardly at portions near the corners 108.
  • the figure shows the effect very exaggeratedly. Creating depressions, such as by a "forcing" process, draws excess material from the walls 116 into the basin 134 and, in essence, shortens the height of the walls at the corners 108.
  • the cathode casing element 104 can be bent to different degrees along its edge 120.
  • the casing element 104 can be bent further along the side portions of the casing element and less along the corner portions.
  • corner portions 139 of the cathode casing element 104 are not bent around the anode casing element 102 to the same degree as portions along the sides of the battery cell 100, making the edge 120 rises slightly around the corner portions 139.
  • This solution reduces corrugation by reducing the amount of shortening deformation near the corner portions 139 while still adequately sealing the casing elements 102, 104 together.
  • the effect of less crimping in the corners can be seen in the cross-sections shown in Figs. 12d(l) and 12d(2).
  • Fig 12d(l) shows a partial cross-section representation of the side portions of the cell
  • Fig. 12d(2) shows a partial cross-section representation of the corner portions of the same cell.
  • air access holes 138 on metal-air battery cells may be a source of electrolyte leakage.
  • the base 112 of the cathode casing element 104 has a plurality of air access holes 138 that are sized and populated to ensure that the air cathode 124 has sufficient access to oxygen. Oxygen is needed by the battery cell 100 to generate current. Increasing the size of the air access holes may increase the supply of oxygen to the air cathode 124. Unfortunately, larger air access holes 138 may also increase the likelihood that electrolyte will leak out through the air access holes 138 and may also increase the rate that the metal anode 122 desiccates.
  • Air access holes 138 may permit electrolyte to freely pass through while smaller air access holes 138 may restrict the flow through the holes 138.
  • the surface tension of a liquid or gel like electrolyte may prevent the electrolyte from passing through smaller sized air access holes 138.
  • Air access holes 138 that have a diameter of 0.4 - 0.5 mm can be repeatedly punched in a metal casing having a thickness of 0.1 - 0.4 mm without undue maintenance of the punches. Smaller sized holes 138 were found to be more difficult to punch.
  • a preferred approach in designing a cathode casing element 104 to limit excessive desiccation and electrolyte leakage while providing sufficient air access is through experimentation.
  • Using an agreed upon and constant dimensions of the air holes 138 determine the electrical energy generated by an agreed upon and constant dimensions of a metal-air battery 10 when different cathode casing elements 104, having different but uniform distances between each air hole 138, are used.
  • the density of the air holes 138 increases, the number of air holes 138 that can fit on the base 112 increases and the total current generated by the battery cell 100 should also increase. At some point, however, the total current will decrease or remain constant. This point occurs when the area supplied by each air hole 138 significantly overlaps the area supplied by an adjacent air hole 138. Further increasing the density of the air holes 138 may unnecessarily increase the rate by which the battery cell 100 desiccates without contributing significantly to the oxygen supply to the air cathode 124.
  • the anode casing element 102 also contains features that increase its strength and improve the reliability of the battery cell 100. Referring now to Fig 13, the peripheral rim 140 and the peripheral trough 142 increase the strength and rigidity of the casing element 102, and do so in substantially the same way as the ledge 132 and the well 134 of the cathode casing element 104. The rim 140 and the trough 142 spread out a concentrated force to the round corners 106 of the anode casing element 102.
  • Fig. 5 showing a collapsing battery cell
  • the side walls are bent so that the peripheral edge 54 is deflected inwardly. This collapse can arise from the external forces applied during the crimping process or from excessive bulging of the base 58 of the anode casing element 52.
  • the strength of its cylindrical shape can resist this type of deformation.
  • the shape is less able to completely resist deformation.
  • the flare of the anode casing element 102 helps to insure that both casing walls 114, 116 cooperate to support the cell 100.
  • the outward flare engages the base 112 of the cathode casing element 104 to ensure that the type of buckling illustrated in Fig. 6 does not occur.
  • the outward flare can also improve the electrical connection between the cathode collector (not shown) and the cathode casing element 104 and also improve the effectiveness of the separator 126.
  • the axial force from the assembling process causes the peripheral rim
  • the axial force also cause the sloping side walls 114 and the ends of the walls to deflect outwardly, which pushes the edges of the air cathode 124 and the separator 126 against the cathode casing element 104 and improves the electrical connection between the cathode current collector and the casing element 104.
  • the cathode current collector (not shown) forms a better electrical connection with the casing element 104.
  • the shape of the peripheral rim 144 provides increased reliability by protecting the grommet 130.
  • the rim 144 directs the sharp edges of the peripheral edge
  • the cutting and punching process that is performed to form the casing element 102 may form a sharp edge 118, and that edge 118 may damage the grommet 130 by digging into and shearing the grommet 130.
  • the rim 144 is shaped so that the edge 118 does not dig into the grommet 130, but rather the smooth surfaces of the rim 144 press against the grommet 130, thereby distributing the axial forces over a larger area of contact.
  • Other examples of alternative shaped rims 144 are illustrated in Figs. 14-18. In Fig.
  • a rim 145 has a bend of approximately 180 degrees, which distances the edge 118 even further from the portion of the grommet most susceptible to damage.
  • a rim 146 has a bend in the opposite direction, or inwardly.
  • the cathode casing element 104 does not need to be shaped to accommodate the space occupied by an outward protrusion of the rim 146.
  • the grommet 130 can be thinner and the anode casing element 102 can be sized to hold a larger quantity of the metal anode 122.
  • a rim 147 is shaped to have two bends.
  • the rim 147 provides the benefits of a thinner grommet 130 and a larger capacity anode casing element 102 as in the previous embodiment.
  • the rim 147 through its multiple bends, provides increased strength and rigidity, making it less susceptible to collapsing. Further, the rim 147 also protects against an undesired chemical reaction between the casing element 102 and the metal anode 122.
  • a casing element made of a nickel-steel-copper triclad can react with a zinc anode to produce hydrogen or to introduce contaminant ions into the electrolyte.
  • the nickel is normally coated to prevent the undesired chemical reaction. However, the nickel may become exposed at the edges 118 during the formation of the casing element 102. In this embodiment, the rim 147 distances the edge 118 away from the metal anode 122. Referring now to Figs. 17 and 18, in an alternative embodiment, the edges are smooth and rounded so that they do not contain sharp edges.
  • the base 110 of the anode casing element 102 has ridges 146 that run from the peripheral trough 142 on one side of the casing element 102 to the peripheral trough 142 on the opposite side.
  • the base 112 of the cathode casing element 104 may also contain ridges, as well. These ridges 146 increase the rigidity of the base 110 and make the casing element 102 less susceptible to deformation under increased internal pressure.
  • the ridges 146 of the anode casing element 102 provide increased strength by transferring external forces on the base 110 to the rim 140 and the trough 142. These ridges 146 may be formed at the same time the cathode casing element 104 is crimped over the anode casing element 102, via an appropriately designed crimping tool. Cold forming ridges 146 on a thin, relatively flat metal surface, such as the major surface 110, creates ridges 146 on both sides of the metal surface and further increases the strength of the base 110.
  • ridges are illustrated in Figs. 20, 21, and 22.
  • Figs. 20 and 21 show two alternative arrangements with ridges 148, 150.
  • Fig. 22 shows an anode casing element 102 with ridges 152 attached to its inner surface.
  • the ridges 152 are relatively thin so as to limit the space it occupies, thereby leaving more room for the metal anode.
  • These ridges 152 also increase the strength of the side walls.
  • the bend 43 is inherently strong. Deforming a cylindrical shaped element so that the edge is bent inwardly creates a very strong hoop that is resistant to extension. The bend 43 can then resist deformation and disengagement of the casing elements 42, 52 through its hoop strength. Also, as explained before, the battery cell 40 remains sealed due to the even distribution of forces around the circumference of the battery cell 40.
  • button cells can be reproduced in prism-shaped cells.
  • a similarly designed bend in a prism-shaped cell does not provide the cell with the same strength and rigidity qualities of a button cell. Bending the casing element over long straight sides can easily be straightened towards its original position.
  • a bend of a mere 45 degrees is not particularly strong considering the lack of compression deformation described above, the dimensions of many types of battery cells, and the "spring back" effect of metal when it is bent.
  • the bend 43 of the cathode casing element 42 springs back and the side wall 46 begins to flare outwardly, the two casing elements 42, 52 may becoming disengaged.
  • Simply increasing the degree of bend does not solve all the problems since it can cause the edges 44 of the cathode casing element 42 to corrugate at the corners and become the source of electrolyte leakage. Further, increasing the degree of bend may cause the cathode casing element 42 to contact the anode casing element 52 resulting in an short circuit.
  • Very thin button cells do not experience the effect of a thicker, bulging battery cell, which may cause the inner casing element to slide out of the C-shaped crimp, or alternatively, cause the crimp to open. Further, the C-shaped crimp occupies an excessive amount of space in the lateral direction, thereby reducing the main benefit of a prism-shaped cell.
  • the cathode casing element 104 is bent or crimped over the peripheral rim 140 of the anode casing element 102, forming a bend 154. Due to the elasticity of metal, the cathode casing element 104 tends to spring back when bent. Although the crimping or bending process causes the material to be deformed well beyond its elastic limit, there may be some elastic rebound. To avoid the elastic rebound and its attendant deleterious effect on the integrity of the seal, the bend 154 should be subjected to a high degree of strain. In the embodiment of Fig. 8 A, the side wall 116 also contains a bend 155 to accommodate the outward protrusion of the rim 144.
  • the bend 154 prevents the casing elements 102, 104 from uncoupling. By bending or crimping the casing element 104 far enough so that a portion of the bend 154 extends towards the base 112, the bend 154 prevents the side walls of the cathode casing element 104 from uncoupling and the casing elements 102, 104 from disengaging.
  • the protrusion of the rim 140 of the anode casing element 102 and the thickness of the grommet 130 prevent the bend 154 from deflecting laterally. Essentially, the bend 154 "hooks" over the rim 140 to prevent the side wall 104 from being pushed out.
  • the bending process can be accomplished by further crimping the peripheral basin 134 by a pinching process so that the outward flare of the side walls 116 is reduced or eliminated. Then, while pressing the anode casing element 102 against the cathode casing element 104, the cathode casing element 104 is crimped around the peripheral rim 140 by a similar pinching process.
  • the anode casing element 102 should be firmly pressed against the cathode casing element 104 and the grommet 130 should be compressed at positions 156 and 158. Compressing the grommet 130 while crimping the cathode casing element 104 improves the seal of the battery cell 100.
  • the resiliency of the grommet 130 can fill any gaps between the casing elements 102, 104 and the grommet 130 that are created if the cathode casing element 104 springs back.
  • the grommet 130 is still at least partially compressed at positions 156 and 158 so that a tight seal is maintained at those points.
  • the resiliency of the grommet 130 forms the seal.
  • the grommet 130 is shaped so that an air filled void 131 is created between the seal near the cathode 156 and the seal near the edge of the cathode portion of the cell casing 158. Without a void 131, any electrolyte that has managed to work its way past the seal at position 156 may be assisted, through a capillary effect, with its migration to the seal at position 158.
  • the void 131 reduces or eliminates this capillary effect by significantly enlarging the channel through which electrolyte can flow.
  • the peripheral basin 134 can be even further crimped so that the side walls 116 of the cathode casing element 104 bow inwardly. Further bending may ensure that the casing element 104 does not peel back from the peripheral rim 140 when internal pressure builds up and the battery cell 100 begins to bulge. Overcrimping may also resist the tendency of the battery cell 100 to bulge at the side walls 114, 116 by compensating for increased pressure buildup. Further, such crimping may increase the interacting forces between the side walls 114, 116, thereby improving the effectiveness of the grommet 130 to seal the battery cell 100. Greater forces between the grommet 130 and the side walls 114, 116 may create a better seal.
  • the resiliency of the grommet 130 also ensures that a seal is maintained between the air cathode 124 and the peripheral ledge 132.
  • the air cathode 124 may contain a generally planar layer of uncompressed Teflon® on the side that faces the base 112.
  • Uncompressed Teflon® is particularly suitable because of its gas permeability properties.
  • Teflon® is not very resilient. The portion of the Teflon® layer that contacts the ledge 132 remains at least partially compressed if the axial forces disappear. Therefore, to ensure that the seal is maintained, the grommet 130 should continuously press the air cathode 124 against the ledge 132 to maintain a seal.
  • the generally planar layer of uncompressed Teflon® is not a necessity and may be replaced with a flat, ring-shaped piece of Teflon®.
  • a Teflon® ring 190 is placed on, and shaped to cover, the flat portions of the ledge 132.
  • the Teflon® ring 190 can also be attached to the air cathode 124, such that the Teflon® ring 190 is positioned between the air cathode 124 and the ledge 132.
  • the air cathode 124 can have a generally planar layer of uncompressed Teflon® and a Teflon® ring 190 attached to the planar layer.
  • Teflon® may further improve the seal between the air cathode 124 and the ledge 132.
  • Teflon® ring 190 eliminates one layer of Teflon® between the air cathode 124 and the diffuser 128. Unnecessary layers of Teflon® can act as barriers between the air cathode 124 and the air access holes 138 and restrict the battery cell's 100 access to oxygen.
  • the prism-shaped battery cell 100 of the present invention resists disengagement through substantially axial, interacting forces between the casing element 102, 104.
  • the cross-section of the curvature of the bend 154 substantially conforms to the shape of the rim 140 so that the lateral or non-axial components of the interacting forces that portions of the casing element 104 exert near the bend 154 and the rim 140 substantially cancel each other out.
  • the remaining axial components of the forces press the anode casing element 102 against the cathode casing element 104.
  • the bend 154 exerts forces on the peripheral rim 140 represented by F, 0 and F ⁇ .
  • the lateral components of the forces F 10X and F ux are substantially equal and opposite.
  • Figs. 25A and 25B illustrate the same battery cell under different internal pressure.
  • the battery cell - which has a cathode casing element shaped to have a bend 172 and an edge 176 and an anode casing element shaped to have a rim 174 - may experience bulging when subjected to a high internal pressure.
  • the side walls of the cathode casing element may flare outwardly as the rim 174 of the anode casing element works its way towards the edge 176 of the cathode casing element. This outward flare may cause the battery cell to bulge and possibly leak electrolyte.
  • the casing elements 102, 104 remain engaged to each other through a severe bend feature, which in the example includes a first bend 168 of approximately 180 degrees and a second bend 170 of approximately 90 degrees.
  • the advantage of this double bend feature is that the negative effects of spring back can be significantly reduced or eliminated. Unlike the bend 154 of the embodiment of Fig.
  • a slight elastic rebound of either of the two bends 168, 170 will not significantly lessen the force that the cathode casing element 104 exerts on the peripheral rim 140 of the anode casing element via the grommet 130.
  • the grommet 130 is compressed at the same time that the bend 154 is formed. Any spring back of the bend 154 must be absorbed by the resiliency of the grommet 130 or electrolyte may leak.
  • a minor spring back of the bends 168, 170 has a much less detrimental effect on the seal of the battery cell because the clamping distance - which is measured from base to the contact point near the bend - does not significantly change. The likelihood of electrolyte leaking through a gap between the casing element is significantly reduced.
  • this embodiment is bent to approximately 90 degrees. While this embodiment may lack some of the benefits of the bends of the embodiments of Figs. 8 A and 26, this embodiment is particularly suitable for battery cells 100 that do not experience a high degree of internal pressure or external forces. The embodiment is much easier and less costly to manufacture and still provides resistance to forces which cause the casing elements to disengage.
  • the casing elements 102, 104 prevent disengagement through a bend 185 of approximately 90 degrees and also through an adhesive attaching the grommet 130 to the casing elements 102, 104.
  • the grommet 130 fills the gap between the casing elements 102, 104 so that the battery cell 100 is sealed and electrolyte does not leak.
  • the grommet 130 is coated with a liquid or semi-liquid sealant to further improve the seal by filling the gaps between the grommet 130 and the side walls 114, 116 and by blocking the small channels in the casing elements 102, 104 caused by scratches on the surface of the side walls 114, 116.
  • Tar has been found to be a particularly suitable substance. It is preferable that the substance be an electrically insulating substance so that a short circuit does not occur.
  • the use of a liquid with a high viscosity, such as tar may eliminate the need for a grommet. Instead the high viscosity liquid can be substituted for the grommet.
  • the shape of the casing elements 102, 104 create areas where the interacting forces between the casing elements 102, 104 are more concentrated, thereby improving the sealing qualities of the grommet 130.
  • the radius of the crimp 154 is greater than the radius of the rim 140 which concentrates the axial forces at approximately location 160.
  • minor peripheral ridges or protrusions 162 create the same effect.
  • a seal can also be improved through the addition of minor peripheral ridges or protrusions of the surface of the grommet 130.
  • Figs. 29A and 29B illustrate how a protrusion 300, formed on a surface of a grommet
  • Fig. 29A illustrates the grommet 302 and a casing element 304 before assembly.
  • a surface 306 of the casing element 304 is rough.
  • the protrusion 300 deforms to take the shape of the rough surface 306 of the casing element 304.
  • the protrusion 300 blocks electrolyte from escaping by filling in any gaps that may have been formed if the casing element 304 were to be pressed against a grommet without a peripheral protrusion.
  • the protrusion 300 is preferably shaped to circumscribe a perimeter of a casing element so that the protrusion 300 effectively seals the space between the two casing elements.
  • a diaper ring 162 can absorb the escaping electrolyte before it completely exits the battery cell 100.
  • the diaper ring 162 is preferably located between the peripheral trough 142 of the anode casing element 102 and the crimp 154 or the edge 120 of the cathode casing element 104.
  • an air cathode 64 is positioned near the base 48 of the cathode casing element 42 so that the air cathode 64 has access to oxygen via air holes (not shown) punched in the base 48.
  • a cathode current collector (not shown) is embedded in the air cathode 64 and provides a means through which electric charge can flow. An edge 66 of the collector is exposed and contacts the cathode casing element 42, thereby electrically connecting the air cathode 64 to the cathode casing element 42.
  • the prior art example illustrates the corner 50 of the cathode casing element 42 as being rounded.
  • a battery cell with interior rounded corner is less reliable.
  • the rounded corner 50 may force the air cathode 64 with the embedded cathode current collector (not shown) to bend and conform to the shape of the rounded corner 50.
  • the edge 66 of the current collector is the means through which the air cathode 64 electrically connects to the cathode casing element 42, a bend may cause the battery cell 40 to electrically disconnect. It is preferred that the edge 66 directly contact, or even better, dig into the cathode casing element 42.
  • the cathode casing element 104 has features which improve reliability and lower costs.
  • the edges of the air cathode 124 and the separator 126 press against the side walls 116 of the cathode casing element 104, thereby ensuring electrical connectivity is maintained between the casing element 104 and a cathode current collector 125 embedded in the air cathode 124.
  • the side walls 116 be substantially perpendicular to the air cathode 124 and the cathode current collector 125. Since only the edges of the cmrent collector 125 are exposed, a less than perpendicular contact may result in the air cathode 104 being electrically disconnected from the casing element 104.
  • the present embodiment eliminates the likelihood that the air cathode 124 will bend and conform to the shape of round interior corners. Further, the embodiment eliminates the need for sharp corners, which can be expensive due to the repeated replacement and sharpening of dies used to make the sharp corners.
  • Another feature of the invention relates to the size and shape of the air cathode 124 and the separator 126.
  • the area dimensions of the air cathode 124 and the separator 126 can be slightly larger than the area dimension that the components are intended to occupy. The slightly larger size ensures that that edges of the components press against the side walls 116, thereby ensuring a tight seal by the separator 126 and electrical connectivity with the current collector 125.
  • Fig. 30C exaggeratedly illustrates the size differences between a surface area representation 175 of the air cathode 124 before assembly and a surface area representation 177 of the area that the air cathode 124 is intended to occupy or "occupied representation".
  • a length L 175 of the pre-assembly representation 175 is longer and a width W 175 is shorter than a length L ]77 and width W 177 of the occupied representation 177, respectively.
  • both the length L 175 and width W 175 of the pre-assembly representation 175 are larger than the respective dimensions of the occupied representation 177, the air cathode 124 may ripple, especially at its corners 179. If the length L 177 of the occupied dimension 177 is longer than its width W 177 , it is preferred that the length L 175 of the pre-assembly representation be longer than the length L 177 of the occupied representation 177. The opposite holds true for the reverse scenario.
  • the air cathode 124 it is preferred (though not necessary) for the air cathode 124 to have an area dimension that is longer than the corresponding area dimension of the occupied representation for that particular area dimension that is the longer of the two area dimensions. This configuration has been found to produce a better electrical connection with less rippling effects.
  • Fig. 31 exaggeratedly illustrates an alternative embodiment where corner sections 191 of a surface area representation 193 of the pre-assembled current collector 127 and the air cathode 124 extend out from a surface area representation 195 of the "occupied representation". These corners sections of the current collector 127 are a means by which the current collector 127 contacts the casing element 104.
  • FIG. 30A and 30B another feature of the basin 134 is that it can be used to catch electrolyte or adhesive that had managed to work its way around the separator 126.
  • a peripheral diaper ring similar to the diaper ring 162 described above, can be placed in the recess of the basin 134 and absorb the electrolyte or adhesive before it can work its way out through the air access holes 138 of the cathode casing element 104.
  • Figs. 32 and 33 showing an alternative embodiment, one of the area dimensions of the air cathode 124 and the separator 126 are larger that the corresponding area dimension of the occupied representation.
  • Fig. 32 which shows the air cathode 124, the separator 126, and the cathode casing element 104 prior to the insertion of the anode casing element 102, the centers of the components 124, 126 bow away from the base 112 to form a gentle curve facing concave down.
  • the components 124, 126 After insertion of the anode casing element 102, as illustrated in Fig. 33, the components 124, 126 become flattened and bent near their edges. The resiliency of the components 124, 126 ensure that the separator 126 adequately seals and that the cathode current collector 125 electrically connects to the casing element 104.
  • a strap 166 resists any deformation and bulging of the battery cell 100.
  • the strap 166 is snap fitted onto the battery cell 100. It is preferred that the strap 166 be made of an insulated and resilient material so that the strap does not cause the battery cell 100 to short circuit.
  • the casing elements can contain a recess shaped to fit the strap 166 so that the strap 166 is at least partially embedded in the cathode and/or anode casing elements 102, 104. The recess can ensure that the strap 166 remains in place and may also make the battery cell easier to connect to the electronic device.
  • an asymmetrical metal- air battery cell 200 has two cathodes 201 positioned on opposite sides of a metal anode 202. Above the two cathodes are two diffusers 203 and two metal cathode casing elements 204 having air holes 205. At least partly embedded in the metal anode 202 is an anode current collector 206, which is connected to an electrical lead 207. Within the pair of air cathodes 201 are a pair of cathode current collectors (not shown), which electrically connect the pair of air cathodes 31 to the respective cathode casing elements 204.
  • a grommet 208 firmly surrounds a portion of the electrical lead 207, thereby preventing the electrolyte from leaving the battery cell 200 via the hole through which the lead 207 passes.
  • the grommet 208 also presses the air cathodes 201 into their respective cathode casing elements 204.
  • the electrical lead 207 can also be molded into the grommet 208 or the grommet 208 can be fitted and caulked to make a seal.
  • the grommet 208 should be made of a resilient material so that the compressive forces of the grommet 208 can seal the two cathode casing elements 204 together.
  • An example of suitable material for a grommet 208 is polysulfone.
  • a pair of semi-rigid straps 209 hold the contents of the battery cell 200 in place via snap-fits located at positions 210.
  • the rigid straps 209 press the two cathode casing elements 204 together, which press against the two air cathodes 201 and compress the grommet 208.
  • the cathode casing elements 204 can be glued directly to the grommet 208, instead.
  • the use of two air cathodes 201 and one anode 202 increases the power of the battery cell 200.
  • both cathodes 201 have approximately the same nominal voltage with respect to ground
  • two straps 211 when snap fitted onto the cathode casing element, substantially surround the perimeter of the battery cell.

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  • Sustainable Development (AREA)
  • Sustainable Energy (AREA)
  • Sealing Battery Cases Or Jackets (AREA)
  • Hybrid Cells (AREA)

Abstract

Cette invention a trait à un élément d'accumulateur métal-air étanche permettant d'éviter toute fuite d'électrolyte par les espaces existant entre les éléments de boîtier de l'élément d'accumulateur ainsi que par des ouvertures ménagées sur l'élément d'accumulateur. En fabriquant les éléments de boîtier et/ou l'anneau placé entre les éléments de boîtier avec au moins un saillant, on obtient un effet de contrainte intense exercé par les éléments de boîtier ainsi que par l'anneau et circonscrivant l'ouverture, ce qui empêche toute fuite d'électrolyte. En ajoutant, également, un liquide à viscosité élevée, enduisant l'anneau ou le remplaçant, on évite quasiment tout risque de fuite d'électrolyte. Il est également possible de placer un joint d'étanchéité constitué d'au moins une couche de Téflon, d'ordinaire non comprimée, dont des parties aplaties sont pressées contre au moins un élément de boîtier. Les forces interactives s'exerçant entre les parties aplaties de la couche de Téflon non compressée et les éléments de boîtier assurent cette fonction d'étanchéification.
PCT/US1999/028421 1998-12-15 1999-12-01 Dispositifs d'etancheite equipant des elements d'accumulateur metal-air et destines a empecher une fuite d'electrolyte WO2000036668A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AU32064/00A AU3206400A (en) 1998-12-15 1999-12-01 Sealing features in metal-air battery cells for the prevention of electrolyte leakage

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
US11229298P 1998-12-15 1998-12-15
US60/112,292 1998-12-15
US29345899A 1999-04-15 1999-04-15
US09/293,458 1999-04-15

Publications (1)

Publication Number Publication Date
WO2000036668A1 true WO2000036668A1 (fr) 2000-06-22

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Family Applications (3)

Application Number Title Priority Date Filing Date
PCT/US1999/028253 WO2000036689A1 (fr) 1998-12-15 1999-11-30 Structure pour element d'accumulateur metal-air en forme de prisme possedant des dispositifs destines a eviter une fuite d'electrolyte et a maintenir la connectivite entre une cathode a air et un element de boitier
PCT/US1999/028421 WO2000036668A1 (fr) 1998-12-15 1999-12-01 Dispositifs d'etancheite equipant des elements d'accumulateur metal-air et destines a empecher une fuite d'electrolyte
PCT/US1999/028558 WO2000036693A1 (fr) 1998-12-15 1999-12-02 Structure pour pile en forme de prisme comportant un joint par contrainte

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PCT/US1999/028253 WO2000036689A1 (fr) 1998-12-15 1999-11-30 Structure pour element d'accumulateur metal-air en forme de prisme possedant des dispositifs destines a eviter une fuite d'electrolyte et a maintenir la connectivite entre une cathode a air et un element de boitier

Family Applications After (1)

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PCT/US1999/028558 WO2000036693A1 (fr) 1998-12-15 1999-12-02 Structure pour pile en forme de prisme comportant un joint par contrainte

Country Status (4)

Country Link
EP (1) EP1142056A1 (fr)
JP (1) JP2002532858A (fr)
AU (3) AU2843500A (fr)
WO (3) WO2000036689A1 (fr)

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WO2002039515A3 (fr) * 2000-11-13 2002-08-01 Electric Fuel Ltd Structure pour un element d'accumulateur metal-air presentant un boitier de laiton
EP2157658A1 (fr) * 2006-03-22 2010-02-24 The Gillette Company Pile zinc-air
US7816026B2 (en) 2006-09-22 2010-10-19 Eveready Battery Company, Inc. Battery having air electrode and biased lever gasket
WO2011037482A1 (fr) * 2009-09-23 2011-03-31 Epin Krzysztof Szymiczek Batterie alcaline zinc-air
EP3373360A1 (fr) * 2017-03-07 2018-09-12 Kabushiki Kaisha Toshiba Module de batterie
CN113273020A (zh) * 2018-09-11 2021-08-17 劲量品牌有限责任公司 具有带槽的垫片的助听器

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US6270921B1 (en) * 2000-01-19 2001-08-07 The Gillette Company Air recovery battery
JP4577702B2 (ja) * 2000-04-13 2010-11-10 東芝電池株式会社 扁平形空気電池
US7238448B1 (en) 2000-04-26 2007-07-03 The Gillette Company Cathode for air assisted battery
US6384574B1 (en) 2000-10-20 2002-05-07 The Gillette Company Battery system
US7097928B1 (en) 2000-10-20 2006-08-29 The Gillette Company Battery and method of making a battery
AU2003901105A0 (en) * 2003-03-12 2003-03-27 Pacific Ore Technology (Australia) Ltd Improved heap leach
JP4804765B2 (ja) * 2004-03-04 2011-11-02 パナソニック株式会社 角形空気電池
CN1321469C (zh) * 2004-03-04 2007-06-13 松下电器产业株式会社 方形空气电池
US8785036B2 (en) * 2012-10-31 2014-07-22 Medtronic, Inc. Electrochemical device and method for assembling an electrochemical device
KR102263435B1 (ko) * 2017-09-13 2021-06-11 주식회사 엘지에너지솔루션 비딩부가 생략된 원통형 전지셀
CN119343812A (zh) * 2022-06-30 2025-01-21 松下新能源株式会社 密闭电池

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Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2002039515A3 (fr) * 2000-11-13 2002-08-01 Electric Fuel Ltd Structure pour un element d'accumulateur metal-air presentant un boitier de laiton
EP2157658A1 (fr) * 2006-03-22 2010-02-24 The Gillette Company Pile zinc-air
US7816026B2 (en) 2006-09-22 2010-10-19 Eveready Battery Company, Inc. Battery having air electrode and biased lever gasket
WO2011037482A1 (fr) * 2009-09-23 2011-03-31 Epin Krzysztof Szymiczek Batterie alcaline zinc-air
EP3373360A1 (fr) * 2017-03-07 2018-09-12 Kabushiki Kaisha Toshiba Module de batterie
US20180261821A1 (en) * 2017-03-07 2018-09-13 Kabushiki Kaisha Toshiba Battery module
US10741816B2 (en) 2017-03-07 2020-08-11 Kabushiki Kaisha Toshiba Battery module
CN113273020A (zh) * 2018-09-11 2021-08-17 劲量品牌有限责任公司 具有带槽的垫片的助听器
CN113273020B (zh) * 2018-09-11 2024-03-26 劲量品牌有限责任公司 具有带槽的垫片的助听器

Also Published As

Publication number Publication date
WO2000036693A1 (fr) 2000-06-22
AU3206400A (en) 2000-07-03
AU2843700A (en) 2000-07-03
EP1142056A1 (fr) 2001-10-10
JP2002532858A (ja) 2002-10-02
WO2000036689A1 (fr) 2000-06-22
AU2843500A (en) 2000-07-03

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