Flat battery and manufacture thereof
First Claim
1. In a flat primary battery structure comprising sheet type separators between electrochemically active battery sheet elements comprising anode materials, cathode materials and electrolyte combined with sheet type electrically conductive intercell connectors and electrically conductive oppositely disposed sheet type current collector elements combined to form a series connected multicell structure by seals entirely surrounding said electrochemically active elements and formed between the peripheries of the sheet type, electrically conductive, intercell connectors and contiguous portions of the sheet type separators;
- the improvement wherein the overall peripheral dimensions of the separators exceed the overall peripheral dimensions of the connectors and active elements and the peripheral dimensions of the intercell connectors exceed the peripheral dimensions of the electrochemically active elements so that the peripheral portions of the separators extend beyond all the peripheral portions of the electrochemically active elements and intercell connectors sealed thereto.
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Accused Products
Abstract
A flat battery structure and method of fabricating it which is characterized by a distinctive integration of the arrangement and dimensions of discrete components of the battery pile structure. Through the select dimensioning and positioning of discrete components of the battery, an especially efficient high speed production process for batteries of improved operational reliability is realized.
38 Citations
32 Claims
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1. In a flat primary battery structure comprising sheet type separators between electrochemically active battery sheet elements comprising anode materials, cathode materials and electrolyte combined with sheet type electrically conductive intercell connectors and electrically conductive oppositely disposed sheet type current collector elements combined to form a series connected multicell structure by seals entirely surrounding said electrochemically active elements and formed between the peripheries of the sheet type, electrically conductive, intercell connectors and contiguous portions of the sheet type separators;
the improvement wherein the overall peripheral dimensions of the separators exceed the overall peripheral dimensions of the connectors and active elements and the peripheral dimensions of the intercell connectors exceed the peripheral dimensions of the electrochemically active elements so that the peripheral portions of the separators extend beyond all the peripheral portions of the electrochemically active elements and intercell connectors sealed thereto. - View Dependent Claims (2, 3, 5, 6, 7, 8, 9)
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4. The battery of claim 4 wherein a said sheet collector element opposite said attached collector element is configured such that a portion thereof is foldable against said electrically insulating sheet material so as to provide a terminal defining surface of said battery.
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10. In a flat battery comprising the combination of:
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means defining a series connected, multicell structure including first and second outwardly disposed electrodes, electrolyte layers and separator means comprising sheet type separators having sheet type electrically conductive intercell connectors whose peripheries are sealed to contiguous portions of said separators to form seals entirely surrounding said electrolyte layers; first and second flat sheet collector means electrically coupled, respectively, with the first and second outwardly disposed electrodes; the improvement wherein the overall peripheral dimensions of the separators exceed the overall peripheral dimensions of the first and second electrodes and of the conductive connectors so that the peripheral portions of the separators extend beyond all the peripheral portions of the electrodes and of the conductive connectors sealed thereto. - View Dependent Claims (11, 12, 13, 14, 15, 16)
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17. In a method for constructing flat battery units comprising the steps of assembling the elements and components of the battery by fixedly placing in selectively spaced alignment a predetermined sequence of electrolyte, anode and cathode materials in combination with discrete sheet type separators and discrete electrically active battery sheet elements including current collectors and sheet type, electrically conductive, intercell connectors to form a discrete series connected, multicell structure assembly by sealing the peripheries of the sheet type, electrically conductive, intercell connectors to contiguous portions of the sheet type separators to form continuous seals entirely surrounding the anode, cathode and electrolyte materials;
the improvement wherein the overall peripheral dimensions of the separators are formed to exceed the overall peripheral dimensions of the connectors sealed thereto, and wherein said connectors are placed within the boundaries of said separators so that said separators overlap said connectors on all sides. - View Dependent Claims (18, 19, 20, 21, 22, 23, 24, 25, 26, 32)
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27. In a method for constructing flat multicell batteries, the steps of:
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providing a continuous carrier sheet of electrically insulative material; fixedly positioning discrete first current collector assemblies in selectively spaced relationship upon said continuous carrier sheet; forming a predetermined number of cells separated by sheet type electrically conductive intercell connectors upon each said collector assembly, each cell including cathode and anode electrodes between which there is disposed electrolyte and a sheet type separator, the electrodes and electrolyte lying within the boundaries of said intercell connectors and said first current collector assembly, and the separator extending beyond the boundaries of said intercell connectors and said first current collector assembly on all sides, by intersealing the peripheries of the sheet type, electrically conductive intercell connectors and said first current collector assembly to contiguous portions of the sheet type separator means, thereby forming continuous seals entirely surrounding the electrodes and electrolyte of all but the outermost cell; positioning discrete second collector assemblies over and in electrical association with the outermost of said cells to form a multicell unit, and sealing said second collector assembly to the outermost separator to complete a continuous seal about the electrodes and electrolyte of said outermost cell, said second collector assemblies having a width selectively extending beyond the edge of said continuous carrier sheet; folding said width of said second collector assembly extending beyond said carrier sheet about the edge thereof to a position juxtaposed against a surface thereof; and sealing the periphery of each said multicell unit. - View Dependent Claims (28, 29, 30, 31)
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Specification