Batteries and battery manufacturing methods

• US 10,629,969 B2
• Filed: 07/27/2014
• Issued: 04/21/2020
• Est. Priority Date: 07/27/2014
• Status: Active Grant

• Current Assignee: Sonova AG (Sonova Holding AG)
• Original Assignee: Sonova AG (Sonova Holding AG)
• Inventors: Lin, Chuangang, Wenzel, Stuart, Wagner, Paul, Au, Michael
• Primary Examiner(s): Barrow, Amanda J
• Application Number:
  US15/326,599
• Publication Number:
  US 20170207506A1
• Time in Patent Office: 2,095 Days
• Field of Search: None
• CPC Class Codes: H01M 12/02 Details of electrodes H01M4/00; of non-active parts H01M50/00
• CPC Class Codes: H01M 12/06 with one metallic and one gaseous electrode

Abstract

A battery manufacturing method including the steps of testing a cathode assembly that includes an air cathode and a battery can cathode portion that is not connected to a battery can anode portion, and joining an anode assembly, including a battery can anode portion in which anode material is located, to the tested cathode assembly.

Claims

1. A method, comprising the steps of:

testing a cathode assembly, that includes an air cathode and a battery can cathode portion that is not connected to a battery can anode portion, by testing leakage of air between surfaces within the battery can cathode portion; and

joining an anode assembly, including a battery can anode portion in which anode material is located, to the tested cathode assembly.

2. The method as claimed in claim 1, wherein

the cathode assembly includes a grommet;

and

the step of testing comprises testing leakage along the grommet.

3. The method as claimed in claim 1, wherein

the step of joining comprises joining the battery can anode portion to the battery can cathode portion by a process selected from the group consisting of adhesive bonding, soldering, brazing, welding, and mechanical interlocking.

4. The method as claimed in claim 1, further comprising the steps of:

prior to joining, selecting from a plurality of anode assemblies, each of which is capable of being joined to the cathode assembly.

5. The method as claimed in claim 1, further comprising the step of

prior to testing, crimping a portion of the battery can cathode portion around the air cathode.

6. The method as claimed in claim 1, further comprising the steps of:

prior to testing, sealing the air cathode within the battery can cathode portion to form the cathode assembly; and

prior to joining, selecting the anode assembly from a plurality of anode assemblies, each of which includes a battery can anode portion in which anode material is located and is capable of being joined to the cathode assembly.

7. The method as claimed in claim 6, wherein

the step of sealing comprises crimping a portion of the battery can cathode portion over the air cathode within the battery can cathode portion.

8. The method as claimed in claim 6, wherein

the step of sealing comprises bonding the air cathode to and within the battery can cathode portion.

9. The method as claimed in claim 6, wherein

the step of joining comprises joining the battery can anode portion to the battery can cathode portion by a process selected from the group consisting of adhesive bonding, soldering, brazing, welding, and mechanical interlocking.

10. The method as claimed in claim 6, wherein

the air cathode includes a gas diffusion barrier that regulates air flow into the air cathode;

and

the step of testing comprises testing air flow into the air cathode.