Flat battery with electrodes in slurry form

• US 4,105,815 A
• Filed: 11/24/1976
• Issued: 08/08/1978
• Est. Priority Date: 08/08/1974
• Status: Expired due to Term

• Current Assignee: Polaroid Corporation (PLR IP Holdings LLC)
• Original Assignee: Polaroid Corporation (PLR IP Holdings LLC)
• Inventors: Buckler, Sheldon A.
• Primary Examiner(s): Lefevour, Charles F.
• Application Number:
  US05/744,871
• Time in Patent Office: 622 Days
• Field of Search: 429/152-162, 429/133, 429/63, 429/199, 429/224, 429/229
• US Class Current: 429/152
• CPC Class Codes: H01M 4/50 of manganese
• CPC Class Codes: H01M 6/06 Dry cells, i.e. cells wherein the electrolyte is rendered non-fluid
• CPC Class Codes: H01M 6/48 with bipolar electrodes
• CPC Class Codes: Y02P 70/50 Manufacturing or production processes characterised by the final manufactured product
• CPC Class Codes: Y10T 29/49114 including adhesively bonding
• CPC Class Codes: Y10T 29/49115 including coating or impregnating

Abstract

Thin flat Leclanche cells and batteries comprising cathodes in the form of slurries of manganese dioxide and carbon in an electrolyte solution containing from 23 to 30 percent of water based on the weight of the slurry. The anodes may be of conventional dry patch construction, or may take the form of slurries of zinc powder in an electrolyte solution containing from 25 to 40 percent of water based on the weight of the anode slurry.

Claims

1. A thin flat laminar battery comprising series connected Leclanche cells in each of which cells there is a zinc anode and a cathode, said cathode comprising a slurry dispersion of MnO₂ and carbon in an electrolyte solution containing zinc chloride, ammonium chloride and from about 23 to about 30 percent of water, based on the weight of dispersion, said dispersion containing a polymeric dispersing agent.

2. A laminar battery comprising series connected superposed Leclanche cells in each of which cells there is a zinc anode and a cathode, said cathode comprising a slurry dispersion of carbon and manganese dioxide in an aqueous solution of electrolytes, said electrolytes comprising a major proportion of ammonium chloride and a minor proportion of zinc chloride by weight, said dispersion containing a polymeric dispersing agent and between 25 and 28 percent of water, based on the total weight of said dispersion.

3. A laminar battery comprising series connected superposed Leclanche cells in each of which cells there is an anode whose electrochemically active ingredient is particulate zinc, and a cathode comprising a slurry dispersion of MnO₂ and carbon in an aqeuous solution of NH₄ Cl and ZnCl₂ and a polymeric dispersing agent, said solution containing between 23 and 30 percent of water by weight, based on the weight of said dispersion.

4. The battery of claim 3 in which said anode in each of said cells comprises a slurry dispersion of zinc particles in an aqueous solution of ammonium chloride and zinc chloride containing from 25 to 40 percent of water by weight based on the weight of said zinc slurry dispersion.

5. A thin flat laminar battery comprising a plurality of superposed cells electrically connected together in series aiding relationship through electronically conducting liquid impervious intercell connectors, said cells each comprising an anode, a cathode, and a separator between said anode and said cathode, said anodes each comprising an anode slurry of zinc powder in an aqueous solution of ammonium chloride and zinc chloride containing from 25 to 40 percent of water by weight based on the weight of said anode slurry, and said cathodes each comprising a cathode slurry of manganese dioxide and carbon black in an aqueous solution of ammonium chloride, zinc chloride and a polymeric dispersing agent containing fron 23 to 30 percent of water by weight, based on the weight of cathode slurry.

6. A planar primary battery including at least two cells positioned intermediate the opposed surfaces of a first and a second current collector and in which each of said cells includes, in combination:

a negative aqueous slurry electrode comprising a substantially uniform particulate dispersion of zinc anode particles in aqueous electrolyte containing a major proportion of ammonium chloride and a minor proportion of zinc chloride, the zinc particles being present in a concentration per unit area effective to provide an electrically conductive dispersion and the electrolyte present in intimate surface contact with the metallic particles in a concentration effective to provide an ionically conductive dispersion, and said zinc dispersion containing from 25 to 40 percent of water based on the weight of said dispersion;

a positive aqueous slurry electrode comprising a substantially uniform particulate dispersion of cathodic mix particles of manganese dioxide and carbon in a substantially uniform distribution of aqueous electrolyte containing a major proportion of ammonium chloride and a minor proportion of zinc chloride, the cathodic particles present in a concentration per unit area effective to provide an electrically conductive dispersion and the electrolyte present in intimate surface contact with the cathodic particles in a concentraton effective to provide an ionically conductive dispersion, said aqueous electrolyte in said positive slurry containing a polymeric dispersing agent and said positive slurry containing from 23 to 30 percent of water by weight, based on the weight of said positive slurry; and

an electrolyte ion permeable separator adapted to be wetted on contact with the electrolyte of the electrodes positioned intermediate the negative and positive electrodes and in contact with said electrolyte of the electrodes.

7. The planar primary battery of claim 6 in which said negative slurry electrode in each of said cells includes a polymeric dispersing agent.

8. The planar primary battery of claim 7 in which said polymeric dispersing agents are hydrophilic polymers.

9. The planar primary battery of claim 6 in which said manganese dioxide and carbon are present, respectively, in a weight-to-weight ratio from between about 6:

1 and 12;

1.

10. The planar primary battery of claim 9 in which said manganese dioxide and carbon are present, respectively, in a weight-to-weight ratio of 8:

1.

11. The planar primary battery of claim 6 including a continuous frame-type electrically insulative sheet seal positioned about each said slurry electrode dispersion and having an inner opening the periphery of which extends outwardly from said dispersion but over the periphery of and adjacent said separator, said seal having an outer peripheral portion extending beyond the peripheries of said first and second current collectors and separator to define continuous border sealing portions, mutually adjacent ones of said seals being mutually intersealed about said border sealing portions and being sealed to adjacent ones of said current collectors.

12. The planar primary battery of claim 6 in which at least said negative slurry electrode aqueous electrolyte further includes mercuric chloride.

13. A thin, flat laminar battery including a plurality of series connected superposed Leclanche cells in each of which there is a manganese dioxide cathode and an anode, said anode consisting essentially of a dispersion of particles of surface amalgamated zinc in an electrolyte solution containing zinc chloride, ammonium chloride, a polymeric dispersing agent, and from about 25 to about 40 percent of water, based on the weight of dispersion.

14. A laminar battery comprising a plurality of series connected superposed Leclanche cells in each of which there is a manganese dioxide cathode and an anode, said anode comprising a dispersion of zinc powder in an aqueous solution of electrolytes, said electrolytes comprising a major proportion of ammonium chloride and a minor proportion of zinc chloride by weight, said dispersion containing between 25 and 40 percent of water, based on the total weight of said dispersion.

15. A laminar battery comprising a series of superposed contiguous Leclanche cells in each of which there is an anode whose electrochemically active ingredient is of particulate zinc dispersed in an aqueous solution of electrolytes containing zinc chloride and ammonium chloride, said zinc dispersion containing from 25 to 35 percent of water based on the weight of said dispersion, and a cathode comprising a cathode dispersion of MnO₂ and carbon in an aqueous solution of electrolytes and a polymeric dispersing agent, said cathode dispersion containing between 23 and 30 percent of water by weight, based on the weight of said dispersion.

16. A laminar battery comprising a series of superposed contiguous Leclanche cells in each of which there is a manganese dioxide cathode and an anode, said anode comprising a dispersion of zinc particles with a minor proportion of carbon particles in an aqueous solution of electrolytes, and a cathode comprising a dispersion of MnO₂ and carbon in an aqueous solution of NH₄ Cl, ZnCl₂, and a polymeric dispersing agent, said solution in the cathode containing between 23 and 30 percent of water by weight, based on the weight of said dispersion.

17. A thin, flat laminar battery comprising a plurality of superposed cells electrically connected together in series aiding relationship through electronically conducting liquid impervious intercell connectors, said cells each comprising an anode, a cathode, and a separator between said anode and said cathode, said anodes each comprising an anode slurry of a major proportion of zinc powder and a minor proportion of carbon black in an aqueous solution of ammonium chloride and zinc chloride containing from 25 to 40 percent of water by weight based on the weight of said anode slurry, and said cathodes each comprising a cathode slurry of manganese dioxide and carbon black in an aqueous solution of ammonium chloride, zinc chloride and a polymeric dispersing agent containing from 23 to 30 percent of water by weight, based on the weight of cathode slurry.

18. A thin, flat laminar battery comprising a series of superposed contiguous Leclanche cells in each of which there is a manganese dioxide cathode and an anode, said anode consisting essentially of a dispersion of particles of surface amalgamated zinc and carbon black in an electrolyte solution containing zinc chloride, ammonium chloride and from about 25 to about 40 percent of water, based on the weight of dispersion.

19. A laminar battery comprising a series of superposed contiguous Leclanche cells in each of which there is a manganese dioxide cathode and an anode, said anode comprising a dispersion of a major proportion of zinc powder and a minor proportion of carbon black in an aqueous solution of electrolytes, said electrolytes comprising a major proportion of ammonium chloride and a minor proportion of zinc chloride by weight, said dispersion containing between 25 and 40 percent of water, based on the total weight of said dispersion.

20. A laminar battery comprising a series of contiguous superposed Leclanche cells in each of which there is an anode comprising of particulate zinc and carbon particles dispersed in an aqueous solution of ammonium chloride and zinc chloride, said anode dispersion containing from 25 to 40 percent of water based on the weight of said dispersion, and a cathode comprising a cathode dispersion of MnO₂ and carbon in an aqueous solution of ammonium chloride and zinc chloride and a polymeric dispersing agent, said cathode dispersion containing between 23 and 30 percent of water by weight, based on the weight of said dispersion.

21. A thin, flat laminar battery suitable for use in high current drain applications without external compressive stress applying members and comprising a plurality of superposed cells electrically connected together in series relationship through flexible electronically conducting liquid impervious intercell connectors, said cells each comprising an anode, a cathode, and a separator between said anode and said cathode, said anodes each comprising an anode slurry of zinc powder in an aqueous solution of ammonium chloride and zinc chloride, said anode slurry containing from 25 to 40 percent of water by weight based on the weight of said anode slurry,, and said cathodes each comprising a slurry of manganese dioxide and carbon black in an aqueous solution of ammonium chloride, zinc chloride and a polymeric dispersing agent, each of said cathode slurries containing between 23 and 30 percent of water by weight, based on the weights of said cathode slurries.

22. A thin, flat primary battery suitable for use in high current drain applications without external compressive stress applying members and including at least one cell positioned intermediate the opposed surfaces of a first and a second current collector, each such cell comprising a negative aqueous slurry electrode comprising a substantially uniform particulate dispersion of zinc particles in aqueous electrolyte, a positive aqueous slurry electrode comprising a substantially uniform particulate dispersion of manganese dioxide and carbon particles in an aqueous electrolyte containing a polymeric dispersing agent, and an electrolyte ion permeable separator adapted to be wetted on contact with the electrolyte of the electrodes positioned intermediate the negative and positive electrodes and in contact with said electrolyte of the electrodes, said aqueous electrolyte in said negative slurry dispersion comprising a solution of ammonium chloride and zinc chloride, said negative slurry dispersion containing from 25 to 40 percent of water based on the weight of said negative slurry dispersion, said aqueous electrolyte in said positive slurry dispersion comprising a solution of ammonium chloride and zinc chloride, and said positive slurry dispersion containing from 23 to 30 percent of water by weight based on the weight of said positive slurry dispersion.

23. A thin, flat laminar battery suitable for use in high current drain applications without external compressive stress applying members and comprising a plurality of superposed cells electrically connected together in series aiding relationship through electronically conducting liquid impervious intercell connectors, said cells each comprising an anode, a cathode, and a separator between said anode and said cathode, said anodes each comprising a slurry of zinc particles in an aqueous solution of electrolyte, and said cathodes each comprising a slurry of manganese dioxide particles in an aqueous solution of electrolytes and containing a polymeric dispersing agent, said electrolytes in said anodes and cathodes comprising ammonium chloride and zinc chloride, each of said anode slurries containing from 25 to 40 percent of water by weight based on the weight of anode slurry, and each of said cathode slurries containing from 23 to 30 percent of water by weight based on the weight of cathode slurry.