Electrical cells and batteries

• US 4,119,770 A
• Filed: 01/24/1977
• Issued: 10/10/1978
• Est. Priority Date: 05/07/1976
• Status: Expired due to Term

• Current Assignee: Polaroid Corporation (PLR IP Holdings LLC)
• Original Assignee: Polaroid Corporation (PLR IP Holdings LLC)
• Inventors: Land, Edwin H.
• Primary Examiner(s): LeFevour, Charles F.
• Application Number:
  US05/761,651
• Time in Patent Office: 624 Days
• Field of Search: 429/133-135, 429/152-162, 429/201, 429/224, 429/229, 429/249
• US Class Current: 429/152
• CPC Class Codes: H01M 4/06 Electrodes for primary cells
• CPC Class Codes: H01M 6/12 with flat electrodes
• CPC Class Codes: H01M 6/48 with bipolar electrodes

Abstract

A thin flat battery comprising a plurality of cells separated by intercell connectors comprising conductive carbon in a thermoplastic resin, in which each cell consists of a cathode comprising a high viscosity mixture of manganese dioxide and carbon dispersed in an aqueous electrolyte solution and without added binder material, a dry patch zinc anode moistened with electrolyte, and a separator of regenerated cellulose between the anode and the cathode.

Claims

1. A flat laminar cell especially adapted for high-current drain applications without requiring external compression and comprising a zinc anode, a manganese dioxide cathode, and a separator consisting essentially of cellophane between said anode and said cathode, said manganese dioxide cathode comprising a slurry of manganese dioxide and carbon particles in an aqueous Leclanche-type electrolyte solution of ammonium chloride and zinc chloride, said manganese dioxide cathode slurry being essentially free of any polymeric binder, and a carbon-filled conductive polymer layer positioned on the other side of said manganese dioxide slurry from said cellophane separator, the water content and ratio of manganese dioxide to carbon being effective to cause said manganese dioxide cathode slurry to adhere to said carbon-filled conductive polymer without the continuous application of external pressure.

2. In a thin flat laminar cell especially adapted for high current drain applications without requiring external compression, a layer of cohesive cathode slurry adhering on one side to a sheet consisting essentially of regenerated cellulose and on the other side to a sheet of conductive plastic, said slurry consisting essentially of manganese dioxide and carbon black in an aqueous electrolyte solution of zinc chloride and ammonium chloride having a pH below 6 and containing at least twenty percent of water by weight of slurry, said slurry being essentially free of binders and being characterized by the retention of substantially all the water without the formation of a film of supernatant liquid at the interface between said slurry and said conductive plastic, said regenerated cellulose separating said cathode slurry from a zinc anode.

3. In a thin flat laminar cell especially adapted for high current drain applications without requiring external compression, a layer of cohesive cathode slurry consisting essentially of manganese dioxide and carbon black in an aqueous electrolyte solution of zinc chloride and ammonium chloride having a pH below 6 and containing at least 20 percent of water by weight of slurry, said slurry being essentially free of binders and being characterized by the retention of substantially all the water without the formation of a film of supernatant liquid at the boundary surfaces of said slurry, a sheet consisting essentially of regenerated cellulose adhering to one side of said slurry layer, and a sheet of conductive plastic adhering to the other side of said slurry layer, said cathode being in slurry form in said aqueous electrolyte said regenerated cellulose separating said cathode slurry from a zinc anode.

4. A thin flat laminar cell comprising a zinc anode, a manganese dioxide cathode, a separator consisting essentially of regenerated cellulose between said anode and said cathode, and an aqueous acidic electrolyte containing ammonium chloride and zinc chloride permeating said anode, said separator and said cathode, said cathode being in slurry form in said aqueous electrolyte.

5. A battery comprising a plurality of cells as defined by claim 4, said cells being connected in series.

6. A thin flat laminar cell especially adapted for high current drain applications without requiring external compression, comprising a conductive cathode current collector consisting essentially of carbon dispersed in a thermoplastic matrix, a layer of cathode mix adhering to said collector and comprising a cohesive dispersion of manganese dioxide and carbon black in an aqueous solution of an electrolyte consisting essentially of a mixture of zinc chloride and ammonium chloride, said cathode mix including in said aqeuous solution at least twenty percent by weight of water based on the total weight of said mix, a separator consisting essentially of regenerated cellulose adhesively united to said cathode mix by contact, and an anode containing zinc as the principal source of electrons bonded to said separator by a layer of gel electrolyte.

7. In a thin flat laminar cell especially adapted for high current drain applications without requiring external compression, a zinc patch anode coated with a layer of acidic gel electrolyte, a layer of cathode slurry comprising carbon black and manganese dioxide dispersed in an acidic electrolyte solution consisting essentially of water, zinc chloride and ammonium chloride and containing at least 20 percent by weight of water based on the total weight of cathode slurry, a separator consisting essentially of humectant-free regenerated cellulose between and in contact with both said gel electrolyte and said cathode slurry layer, and an electrolytic medium having a pH below 6 ionically connecting said anode to said cathode through said separator.

8. A thin, flat laminar cell especially adapted for high current drain applications without requiring external compression, comprising a conductive cathode current collector consisting essentially of carbon dispersed in a thermoplastic matrix, a layer of cathode mix adhering to said collector and comprising a cohesive dispersion of manganese dioxide and carbon black in an aqueous solution of an electrolyte, said electrolyte comprising water, zinc chloride and ammonium chloride, said cathode mix including in said aqeuous solution at least twenty percent by weight of water based on the total weight of said mix, said cathode mix being free of binders, a separator consisting essentially of regenerated cellulose adhesively united to said cathode mix by contact, and an anode containing zinc as the principal source of electrons bonded to said separator by a layer of gel electrolyte.

9. In a thin, flat laminar cell especially adapted for high current drain applications without requiring external compression, a zinc patch anode coated with a layer of acidic gel electrolyte, a layer of cathode slurry comprising carbon black and manganese dioxide dispersed in an acidic electrolyte solution consisting essentially of water, zinc chloride and ammonium chloride and containing at least 20 percent by weight of water based on the total weight of cathode mix, said cathode slurry being free of binders, and a separator consisting essentially of humectant-free regenerated cellulose between and in contact with said gel electrolyte and said cathode mix layer, said anode being ionically connected to said cathode through electrolyte permeating said separator.