Method of making flat batteries

• US 4,137,627 A
• Filed: 11/18/1977
• Issued: 02/06/1979
• Est. Priority Date: 01/24/1977
• Status: Expired due to Term

• Current Assignee: Polaroid Corporation (PLR IP Holdings LLC)
• Original Assignee: Polaroid Corporation (PLR IP Holdings LLC)
• Inventors: Kinsman, Gordon F.
• Primary Examiner(s): Lanham, C. W.
• Assistant Examiner(s): Crane, Daniel C.
• Application Number:
  US05/852,916
• Time in Patent Office: 445 Days
• Field of Search: 29/623.1, 29/623.2, 29/623.3, 29/623.4, 29/423, 29/424, 429/152, 429/153, 429/154, 429/155, 429/162, 141/1.1, 141/33
• US Class Current: 29/623.4
• CPC Class Codes: H01M 6/48 with bipolar electrodes
• CPC Class Codes: Y10T 29/4911 including sealing
• CPC Class Codes: Y10T 29/49114 including adhesively bonding
• CPC Class Codes: Y10T 29/4981 Utilizing transitory attached element or associated separate material

Abstract

A frame and separator assembly for the manufacture of thin, flat laminar batteries in which the frame has adhesive surfaces to which a separator is adhered. The method of making batteries in which these assemblies are placed over electrode slurries extruded onto conductive plastic substrates and the separators are coated with electrolyte and then contacted with dry patch anodes on conductive plastic substrates to form cells.

Claims

1. In the method of manufacturing a thin, flat laminar battery, the steps of forming a first thin, dry patch anode layer over a central region of the surface of a first sheet of liquid impervious conductive plastic material, extruding a layer of wet slurry cathode material over a surface of said sheet opposite said dry patch anode, temporarily heat sealing a cellophane separator to one surface of a liquid impervious thermoplastic frame over an opening formed in said frame adapted to receive said cathode slurry layer, placing the side of said frame opposite said separator in contact with said first sheet with said cathode slurry in said opening, coating the exposed surface of said separator with gel electrolyte, forming a second thin, dry patch anode layer over a central region of the surface of a second sheet of liquid impervious conductive plastic material congruent with said first sheet, and placing said second sheet over said frame with said second anode patch in registry and in contact with said gel electrolyte.

2. In a method of making a thin, flat laminar battery, the steps of extruding a first wet slurry cathode layer over a region of the surface within the periphery of a liquid impervious conductive plastic sheet, heat sealing a cellophane separator over a central opening formed in a frame of liquid impervious insulating material at least the exterior surface of which comprises a thermoplastic hot melt adhesive material, placing said frame over said sheet with said first cathode slurry in the opening in said frame with said separator thereon exposed, coating said separator with a layer of gel electrolyte, forming a dry patch anode layer over a central region of the surface of a sheet of liquid impervious conductive plastic material, and placing said sheet over said frame with the anode layer thereon in contact with the gel electrolyte on said separator.

3. In the method of manufacturing a thin, flat laminar battery, the steps of forming a first electrode layer over a central region of the surface of a first sheet of liquid impervious conductive plastic material, extruding a layer of wet slurry electrode material over a surface of said sheet opposite said first electrode, temporarily heat sealing a separator to one surface of a liquid impervious thermoplastic frame over an opening formed in said frame adapted to receive said slurry electrode, placing the side of said frame opposite said separator in contact with said first sheet with said wet slurry electrode in said opening, coating the exposed surface of said separator with electrolyte, forming a third electrode layer of the same composition as said first electrode layer over a central region of the surface of a second sheet of liquid impervious conductive plastic material congruent with said first sheet, and placing said second sheet over said frame with said third electrode layer in registry and in contact with said electrolyte.

4. In a method of making a thin, flat laminar battery, the steps of extruding a first wet slurry cathode layer over a region of the surface within the periphery of a first liquid impervious conductive plastic sheet, sealing a separator over a central opening formed in a frame of liquid impervious insulating material at least the exterior surface of which comprises a thermoplastic hot melt adhesive material, placing said frame over said sheet with said first cathode slurry in the opening in said frame with said separator thereon exposed, coating said separator with a layer of electrolyte, forming an anode layer over a central region of the surface of a second sheet of liquid impervious conductive plastic material, and placing said second sheet over said frame with the anode layer thereon in contact with the electrolyte on said separator.

5. In the method of manufacturing a thin, flat laminar battery, the steps of forming a first thin, dry patch anode layer over a central region of the surface of a first sheet of liquid impervious conductive plastic material, extruding a layer of wet slurry cathode material over a surface of said sheet opposite said dry patch anode, temporarily heat sealing a cellophane separator to one surface of a liquid impervious thermoplastic frame over an opening formed in said frame adapted to receive said cathode slurry layer, placing said frame in contact with said first sheet with said cathode slurry in registry with said opening and in contact with said separator, coating the exposed surface of said separator with gel electrolyte, forming a second thin, dry patch anode layer over a central region of the surface of a second sheet of liquid impervious conductive plastic material congruent with said first sheet, and placing said second sheet over said frame with said second anode patch in registry and in contact with said gel electrolyte.

6. In a method of making a thin, flat laminar battery, the steps of extruding a first wet slurry cathode layer over a region of the surface within the periphery of a liquid impervious conductive plastic sheet, heat sealing a cellophane separator over a central opening formed in a frame of liquid impervious insulating material at least the exterior surface of which comprises a thermoplastic hot melt adhesive material, placing said frame over said sheet with said first cathode slurry in registry with the opening in said frame and in contact with said separator, coating said separator with a layer of gel electrolyte, forming a dry patch anode layer over a central region of the surface of a sheet of liquid impervious conductive plastic material, and placing said sheet over said frame with the anode layer thereon in contact with the gel electrolyte on said separator.

7. In a method of making a thin, flat laminar battery, the steps of extruding a first wet slurry cathode layer over a region of the surface within the periphery of a first liquid impervious conductive plastic sheet, sealing a separator over a central opening formed in a frame of liquid impervious insulating material at least the exterior surface of which comprises a thermoplastic hot melt adhesive material, placing said frame over said sheet with said first cathode slurry in registry with the opening in said frame and in contact with said separator, coating said separator with a layer of electrolyte, forming an anode layer over a central region of the surface of a second sheet of liquid impervious conductive plastic material, and placing said second sheet over said frame with the anode layer thereon in contact with the electrolyte on said separator.

8. In the method of manufacturing a thin, flat laminar battery, the steps of extruding a layer of wet slurry cathode material over a central region of a first surface of a first sheet of liquid impervious conductive plastic material having a first thin, dry patch anode layer on a central region of a second surface of said sheet opposite said first surface, temporarily heat sealing a cellophane separator to one surface of a liquid impervious thermoplastic frame over an opening formed in said frame adapted to receive said cathode slurry layer, placing said frame in contact with said first sheet with said cathode slurry in registry with said opening and in contact with said separator, coating the exposed surface of said separator with gel electrolyte, placing a second sheet of liquid impervious conductive plastic material having a second thin, dry patch anode layer on a central region of its surface over said frame with said second anode patch in registry and in contact with said gel electrolyte.

9. In a method of making a thin, flat laminar battery, the steps of extruding a first wet slurry cathode layer over a region of the surface within the periphery of a liquid impervious conductive plastic sheet, heat sealing a cellophane separator over a central opening formed in a frame of liquid impervious insulating material at least the exterior surface of which comprises a thermoplastic hot melt adhesive material, placing said frame over said sheet with said first cathode slurry in registry with the opening in said frame and in contact with said separator, coating said separator with a layer of gel electrolyte, and placing a sheet of liquid impervious conductive plastic material having a dry patch anode layer on a central region of its surface over said frame with the anode layer thereon in contact with the gel electrolyte on said separator.

10. In a method of making a thin, flat laminar battery, the steps of extruding a first wet slurry cathode layer over a region of the surface within the periphery of a first liquid impervious conductive plastic sheet, sealing a separator over a central opening formed in a frame of liquid impervious insulating material at least the exterior surface of which comprises a thermoplastic hot melt adhesive material, placing said frame over said sheet with said first cathode slurry in registry with the opening in said frame and in contact with said separator, coating said separator with a layer of electrolyte, and placing a second sheet of liquid impervious conductive plastic material having an anode layer on a central region of its surface over said frame with the anode layer thereon in contact with the electrolyte on said separator.

11. In a method of making a thin, flat laminar battery, the steps of extruding a first wet slurry cathode layer over a region of the surface within the periphery of a liquid impervious conductive plastic sheet, placing a frame of liquid impervious insulating material at least the exterior surface of which comprises a thermoplastic hot melt adhesive material and having a cellophane separator temporarily bonded over said opening over said sheet with said first cathode slurry in registry with the opening in said frame and in contact with said separator, coating said separator with a layer of gel electrolyte, and placing a sheet of liquid impervious conductive plastic material having a dry patch anode layer on a central region of its surface over said frame with the anode layer thereon in contact with the gel electrolyte on said separator.