Method of manufacturing metal air cell system

• US 20040031143A1
• Filed: 06/02/2003
• Published: 02/19/2004
• Est. Priority Date: 05/31/2002
• Status: Abandoned Application

• Current Assignee: Evionyx Incorporated (Reveo, Inc.)
• Original Assignee: Evionyx Incorporated (Reveo, Inc.)
• Inventors: Morris, William, Tsai, Tsepin
• Application Number:
  US10/452,833
• Publication Number:
  US 20040031143A1
• Time in Patent Office: Days
• US Class Current: 29/623.4
• CPC Class Codes: H01M 12/08 composed of a half-cell of a fuel-cell type and a half-cell of the secondary-cell type
• CPC Class Codes: H01M 50/103 prismatic or rectangular H01M50/109, H01M50/11 take precedence
• CPC Class Codes: H01M 50/186 characterised by the disposition of the sealing members
• CPC Class Codes: H01M 50/193 Organic material
• CPC Class Codes: H01M 50/489 Separators, membranes, diaphragms or spacing elements inside the cells, characterised by their physical properties, e.g. swelling degree, hydrophilicity or shut down properties
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y10T 29/49114 including adhesively bonding

Abstract

The present invention provides a method of manufacturing metal air cell systems. The method includes a thermoset molding step to integrate the cell structure with necessary cell components. This method offers reliable, stable structure and, most importantly, good bonding with porous components (e.g., air cathode, charging cathode) to prevent potential leakage.

Claims

1. A method of forming a metal air cell frame comprising:

molding a housing integrating periphery edges of an air diffusion electrode.

10. The method as in claim 1 or 2, wherein casting is at ambient temperatures and pressures.

2. A method of forming a metal air cell frame comprising:

providing a mold configured for supporting an air diffusion electrode and configured for

providing a space for an anode and an ionic conducting medium;

inserting the air diffusion electrode in the mold;

inserting a spacer for the space for the anode; and

introducing frame constituent material into the mold to produce the metal air cell frame.

3. The method as in claim 2, further wherein mold is configured for supporting an air frame portion proximate the cathode element.

4. The method as in claim 2, wherein frame constituent material seals edges of the cathode element.

5. The method as in claim 2, wherein frame constituent material comprises urethane which polymerizes in to polyurethane.

6. The method as in claim 5, wherein the polyurethane polymerizes in situ at edges of the cathode element.

7. The method as in claim 2, further wherein mold is configured for supporting a cathode current collector

8. The method as in claim 2, wherein mold is configured for pour casting.

9. The method as in claim 2, wherein mold is configured for reaction injection molding.