Battery

• US 5,567,544 A
• Filed: 05/26/1995
• Issued: 10/22/1996
• Est. Priority Date: 05/26/1995
• Status: Expired due to Fees

• Current Assignee: Boundless Technologies Incorporated (Video Display Corporation)
• Original Assignee: Boundless Technologies Incorporated (Video Display Corporation)
• Inventors: Lyman, Philip C.
• Primary Examiner(s): Valentine, Donald R.
• Application Number:
  US08/452,423
• Time in Patent Office: 515 Days
• Field of Search: 429/95, 429/149, 429/152, 429/153, 429/154, 29/623.3, 29/623.4
• US Class Current: 429/152
• CPC Class Codes: H01M 10/0431 Cells with wound or folded electrodes H01M10/045 takes precedence
• CPC Class Codes: H01M 10/0436 Small-sized flat cells or batteries for portable equipment
• CPC Class Codes: H01M 10/30 Nickel accumulators H01M10/34 takes precedence
• CPC Class Codes: H01M 10/345 Gastight metal hydride accumulators
• CPC Class Codes: H01M 4/808 Foamed, spongy materials
• CPC Class Codes: H01M 6/16 with organic electrolyte H01M6/18 takes precedence
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• 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

Abstract

A battery assembled in the form of a lightweight structural panel and including isolated battery cells. Each of the cells includes a honeycomb structure wherein each film-like layer in the honeycomb structure is an electrode stack. Each of the electrode stacks includes an elongated cathode, an elongated separator, and an elongated anode. The separator is wetted with an electrolyte solution to facilitate the electrochemical reaction. The electrochemical reaction may be that of an NiMH2 battery, an NiH battery, an Li⁺ battery, an NiCd battery, a Lead-acid battery, or any other suitable electrochemical reaction. Alternatively, the battery cell could be composed of a foam-like cathode, foam-like separator, and a foam-like anode. With either embodiment, the invention achieves the storage of electrochemical energy in a structure with a multitude of voids defined therein so that the structure is relatively stiff, yet light weight.

Claims

1. A battery for supplying power to an electrical circuit having a first terminal and a second terminal, comprising:

an elongated anode including a first reagent, the anode being connectable to the first terminal of the circuit;

an elongated cathode positioned adjacent and in spaced-apart relation to the anode, the cathode including a second reagent and being connectable to the second terminal of the circuit;

a separator positioned between the anode and the cathode which provides electrical insulation between the anode and the cathode yet permits an electrochemical reaction to occur involving the transfer of ions between the anode and cathode, the transfer of ions allowing electrical current to flow from the cathode through the circuit to the anode of the battery;

wherein the anode, the separator, and the cathode form an elongated electrode stack; and

wherein a plurality of elongated electrode stacks are connected together in a honeycomb structure.

2. A battery as defined in claim 1, wherein the separator is permeable and is wetted with an electrolyte solution which allows the electrochemical reaction involving the first and second reagents to occur, in which ions are transferred between the reagents to allow electrical current to flow from the cathode through the circuit to the anode of the battery.

3. A battery as defined in claim 1, wherein the anode includes a support layer and a reagent layer.

4. A battery as defined in claim 1, wherein the anode includes a current collector layer and a reagent layer.

5. A battery as defined in claim 1, wherein the anode includes a support layer, a current collector layer, and a reagent layer.

6. A battery as defined in claim 1, wherein the cathode includes a support layer and a reagent layer.

7. A battery as defined in claim 1, wherein the cathode includes a current collector layer and a reagent layer.

8. A battery as defined in claim 1, wherein the cathode includes a support layer, a current collector layer, and a reagent layer.

9. A battery as defined in claim 1, wherein the anode and cathode are bonded to the separator.

10. A battery as defined in claim 9, wherein the anode and cathode are bonded to the separator by spot welds.

11. A battery as defined in claim 2, wherein the first reagent includes a metal-hydride, the second reagent includes nickel-hydroxide, and the electrolyte solution includes potassium-hydroxide.

12. A battery as defined in claim 1, wherein the honeycomb structure is formed by applying adhesive at a series of regular, spaced-apart positions between each pair of adjacent electrode stacks.

13. A battery as defined in claim 12, wherein the positions of the adhesive between any pair of adjacent electrode stacks is offset from the positions of the adhesive between one of the pair of adjacent electrode stacks and the oppositely-adjacent electrode stack.

14. A battery as defined in claim 13, wherein the separator includes at least one region of solid material adjacent to and corresponding to each of the adhesive positions.

15. A battery as defined in claim 1, wherein a plurality of separate honeycomb structures are each combined as separate cells into a battery panel including:

an insert frame which receives each of the plurality of separate cells; and

a pair of faceplates, an upper faceplate and a lower faceplate, which are attached to the insert frame from opposite sides to sandwich the cells therein.

16. A battery as defined in claim 15, wherein the faceplates are attached to the insert frame and to the separate cells by adhesive, the attachment to the insert frame being made by electrically-insulating adhesive and the attachment to the separate cells being made by electrically-conducting adhesive.

17. A battery as defined in claim 15, further including a plurality of edge closures peripherally outside of the insert frame and the separate cells and also sandwiched between the faceplates.

18. A battery as defined in claim 16, wherein the first reagent includes a metal-hydride, the second reagent includes nickel-hydroxide, and the electrolyte solution includes potassium-hydroxide;

wherein the separator is permeable and is wetted with the electrolyte solution which allows an electrochemical reaction involving the first and second reagents to occur, in which ions are transferred between the reagents to allow electrical current to flow from the cathode through the circuit to the anode of the battery;

wherein the anode and the cathode each include a support layer, a current collector layer, and a reagent layer;

wherein the anode and cathode are bonded to the separator by spot welds; and

wherein the honeycomb structure is formed by applying adhesive at a series of regular, spaced-apart positions between each pair of adjacent electrode stacks and the positions of the adhesive between any pair of adjacent electrode stacks is offset from the positions of the adhesive between one of the pair of adjacent electrode stacks and the oppositely-adjacent electrode stack and the separator includes at least one region of solid material adjacent to and corresponding to each of the adhesive positions.

19. A battery as defined in claim 2, wherein the first reagent is a hydrogen catalyst, the second reagent includes nickel-hydroxide, and the electrolyte solution includes potassium-hydroxide.

20. A battery as defined in claim 19, wherein the hydrogen catalyst is platinum.

21. A battery as defined in claim 1, wherein the first reagent is a source of lithium ions and the second reagent is a material which can receive and store lithium ions.

22. A battery as defined in claim 21, wherein the source of lithium ions is lithium metal and the material which can receive and store lithium ions is manganese-dioxide.

23. A battery as defined in claim 1, wherein the electrochemical reaction is reversible so that energy may be stored in the battery by charging the battery and the energy may be extracted from the battery by discharging the battery.

24. A battery as defined in claim 5, wherein a nickel plasma is sputtered onto a thin film to form the current collector layer on the substrate layer and a metal-hydride is deposited on the nickel current collector layer to form the reagent layer.

25. A battery as defined in claim 8, wherein a nickel plasma is sputtered onto a thin film to form the current collector layer on the substrate layer and a layer of nickel-hydroxide is deposited thereon.

26. A battery as defined in claim 1, further including a second separator and second cathode positioned adjacent to the anode and on an opposite side of the anode from the first separator and first cathode.

27. A battery as defined in claim 2, wherein a separate half-reaction occurs between the anode and the electrolyte solution and a complementary and separate half-reaction occurs between the cathode and the electrolyte solution.

28. A method for assembling a battery, comprising the steps of:

providing an elongated anode including a first reagent;

providing an elongated cathode including a second reagent;

providing an elongated, porous separator;

bonding the anode and cathode to opposite sides of the separator to form an elongated electrode stack;

assembling a plurality of elongated electrode stacks into a honeycomb structure; and

wetting the separator with an electrolyte.

29. A method as defined in claim 28, wherein the separator includes a plurality of continuous solid portions;

and

wherein the bonding step includes spot welding the anode and cathode to the separator by heating each of the continuous, solid portions to a temperature approaching the melting point of the solid portion of the separator while applying pressure to force the anode and cathode toward the solid portion.

30. A method as defined in claim 28, wherein the honeycomb structure defines a battery cell, the method further including the steps of:

isolating a plurality of the battery cells from each other;

encasing the plurality of isolated battery cells within a shell to form a battery panel; and

providing electrical feed-throughs from the battery cells to the exterior of the shell.