Flat battery

• US 4,028,479 A
• Filed: 01/27/1976
• Issued: 06/07/1977
• Est. Priority Date: 12/26/1974
• Status: Expired due to Term

• Current Assignee: Polaroid Corporation (PLR IP Holdings LLC)
• Original Assignee: Polaroid Corporation (PLR IP Holdings LLC)
• Inventors: Fasolino, Ludwig G., Fanciullo, Ralph D.
• Primary Examiner(s): Skapars, Anthony
• Application Number:
  US05/652,735
• Time in Patent Office: 497 Days
• Field of Search: 136/111, 136/175, 136/133, 429/152, 429/162, 429/210, 429/149
• US Class Current: 429/152
• CPC Class Codes: H01M 6/48 with bipolar electrodes

Abstract

A thin battery of the Le Clanche type incorporating a multiplicity of electrically conductive layers and sheet separators arranged to cooperate in conjunction with electrochemical material to form a multicell battery. Continuous frame-type sheet seals are thermally bonded to the periphery of each of the separator and conductive layers to provide an insulative sealing arrangement. The outer peripheries of these frames also are heat sealed to provide a rigid, secure border seal for the battery assembly. The sheet separators are positioned intermediate superpositioned ones of the electrically conductive layers.

Claims

1. In a thin planar battery having a multiplicity of discrete electrically conductive polymeric layers arranged in cooperative electrical association with one another to form a multicell battery, the improvement comprising:

continuous frame-type electrically insulative sheet sealing means providing an opening defined by an inner border and having a first surface bonded to a peripheral surface of each discrete electrically conductive polymeric layer, said sheet sealing means extending outwardly from the periphery of the so bonded electrically conductive layer to define a continuous border sealing portion; and

discrete, sheet-type separator means positioned between the electrically conductive layers and having a periphery extending beyond the sealing means inner opening and within said border sealing portion which periphery is bonded to the surface of the sealing means opposite the first surface.

2. A battery of claim 1 in which each bond is a thermal bond.

3. A battery of claim 1 in which the separator means is formed of electrolyte impregnable paper.

4. A battery of claim 3 in which the paper is Kraft paper.

5. A battery of claim 1 in which the frame-type electrically insulative sheet sealing means are formed of polyvinyl chloride.

6. A battery of claim 3 in which the separator means is formed of Kraft paper having a thickness of about 2.5 mils and the frame-type insulative sheet sealing means is formed of polyvinyl chloride having a thickness of about 5 mils.

7. A laminar battery comprising:

discrete, sheet-type electrically conductive electrode supports at least one of which is formed having a predetermined periphery shape and arranged in superpositioned fashion in combination with electrode material and electrolyte to define at least one electrochemical cell;

electrically insulative frames, each having an opening defined by an inner border, a first continuous sealing surface extending outwardly from the inner border with peripheral portions of the electrode support bonded to the first sealing surface said frame being dimensioned to extend beyond the peripheral portions of the electrode support to provide a continuous second sealing surface for intersealing superpositioned frames at the second sealing surface; and

discrete, sheet-type separator means positioned between the electrode supports and shaped to provide a periphery extending beyond the frame opening but within the second sealing surface which periphery is bonded to the surface of the frame opposite the first sealing surface.

8. A battery of claim 7 in which the bonds are thermally induced.

9. A battery of claim 7 in which the separator means is a sheet material shaped coextensive with the peripheral shape of the electrode support.

10. A battery of claim 7 in which the separator means is formed of electrolyte impregnable paper.

11. A battery of claim 7 in which the paper is Kraft paper.

12. The laminar battery of claim 7 in which said frames are formed of sheet polyvinyl chloride.

13. The laminar battery of claim 7 in which said separator means is formed on Kraft paper having a thickness of about 2.5 mils and said frame is formed of polyvinyl chloride having a thickness of about 5 mils.

14. The laminar battery of claim 7 in which the outwardly disposed ones of said discrete sheet-type electrically conductive electrode supports are formed as current collector assemblies comprising an outwardly facing metal foil coextensive and in electrical bond with the outward facing surface of said electrode support so as to provide a terminal contact surface for said battery.

15. The laminar battery of claim 7 in which one said current collector assembly is configured such that a portion thereof is foldable toward the oppositely disposed one of said current collector assemblies and including means electrically insulating said folded portion from said oppositely disposed collector assembly so as to provide adjacent terminal defining surfaces.

16. The laminar battery of claim 7 in which said electrode material includes positive and negative material, said positive material comprising manganese dioxide active material, said negative material comprises zinc active material, and said electrolyte comprises ammonium chloride and/or zinc chloride.

17. The laminar battery of claim 7 in which said first continuous sealing surface of said electrically insulative frames are sealed thermally to said electrode supports on a surface thereof supporting said negative material.

18. The laminar battery of claim 7 in which said frames are formed of polyvinyl chloride and said separator means are formed of Kraft paper.