Method for manufacturing flat batteries
First Claim
1. In a method for constructing multicell batteries wherein intermittent deposits of electrode materials, separator means and electrolyte are provided in spaced relationship along select zones over a continuous electrically conductive polymeric web, at least one select zone of said web present at an initial stage of said method as a laminate of said polymeric material and continuous metal material for deriving externally disposed metal current collector surfaces of said batteries, said zones being compiled and subsequently severed transversely and parallel to the manufacturing flight line direction of zone movement to derive discrete ones of said batteries, the improvement comprising the step of removing select portions of said sheet metal material to provide discrete and mutually spaced components of said sheet metal remaining laminated with said continuous polymeric material to define discrete current collector assemblies for said batteries.
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Abstract
A method for manufacturing flat or planar batteries wherein a carbon-impregnated polymeric carrier web which is selectively zonally prelaminated with continuous strips of metal ultimately serving current collector purposes is machined to form discrete current collctor subassemblies as an initial step of production. Through the use of select laser cutting, geometries of individual battery elements are maintained. Chemical milling techniques may be utilized for the noted metal removal.
118 Citations
28 Claims
- 1. In a method for constructing multicell batteries wherein intermittent deposits of electrode materials, separator means and electrolyte are provided in spaced relationship along select zones over a continuous electrically conductive polymeric web, at least one select zone of said web present at an initial stage of said method as a laminate of said polymeric material and continuous metal material for deriving externally disposed metal current collector surfaces of said batteries, said zones being compiled and subsequently severed transversely and parallel to the manufacturing flight line direction of zone movement to derive discrete ones of said batteries, the improvement comprising the step of removing select portions of said sheet metal material to provide discrete and mutually spaced components of said sheet metal remaining laminated with said continuous polymeric material to define discrete current collector assemblies for said batteries.
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10. The method for constructing planar multicell batteries comprising the steps of:
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providing a continuous web of electrically conductive polymeric material, said material having a plurality of zones defined across its widthwise dimension, at least one said zone representing a lamination of said web with a continuous layer of metallic material; moving said web in a manufacturing flight line direction parallel with the lengthwise dimension of said web; selectively removing said metallic material from said web in a manner defining a continuous succession of discrete selectively dimensioned and mutually spaced laminar collector assemblies; providing spaced, intermittent deposits of select electrode active material along said zones; selectively combining said electrode material deposits with separator means, sealing means and electrolyte; isolating said zones by initially severing said web at the boundaries of said zones parallel to said flight line direction; compiling said zones to bring said electrode material deposits, electrolyte, sealing means and separator means into registry to form multicell pile structures; sealing the peripheries of said multicell pile structures; and severing said web transversely to said flight line direction at locations intermediate said spaced collector assemblies to provide discrete multicell batteries. - View Dependent Claims (11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24)
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25. The method for constructing planar multicell batteries comprising the steps of:
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providing a continuous thin web of carbon impregnated polymeric sheet material, said material having a plurality of zones defined across its widthwise dimension, at least one said zone representing a lamination of said web with a continuous sheet of metal current collector material; moving said web in a manufacturing flight line direction; removing select portions of said metal material from said web by chemically machining to provide a continuous succession of discrete, selectively dimensioned and mutually spaced laminar collector assemblies; placing spaced, intermittent deposits of electrode material along said zones; overlaying select said zones with separator means and sealing means combined in continuous web form of multizone width; depositing gel electrolyte in the regions of said electrode deposits; isolating said zones by initially laser cutting said polymeric web and said separator means and sealing means web at the boundaries of said zones parallel to said flight line direction; compiling said zones to bring said electrode material deposits, said electrolyte, sealing means and separator means into registry to form multicell pile structures; thermally sealing said multicell pile structures about the peripheries thereof; and severing said compiled web zones transversely to said flight line direction intermediate said spaced collector assemblies by laser cutting to provide discrete multicell batteries. - View Dependent Claims (26, 27, 28)
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Specification