Battery case

• US 6,004,689 A
• Filed: 12/07/1998
• Issued: 12/21/1999
• Est. Priority Date: 09/27/1995
• Status: Expired due to Fees

• Current Assignee: GP Batteries International Limited (Gold Peak Industries Limited)
• Original Assignee: Bolder Biotechnology, Inc.
• Inventors: Walker, Thomas P., Juergens, Tristan E.
• Primary Examiner(s): KALAFUT, STEPHEN J
• Application Number:
  US09/206,812
• Time in Patent Office: 379 Days
• Field of Search: 429/53, 429/159, 429/175, 429/177, 429/178, 429/179, 429/180, 429/181, 429/182, 429/183, 429/184
• US Class Current: 429/53
• CPC Class Codes: H01M 10/125 Cells or batteries with wound or folded electrodes
• CPC Class Codes: H01M 10/425 Structural combination with electronic components, e.g. electronic circuits integrated to the outside of the casing printed circuits H05K1/00
• CPC Class Codes: H01M 10/46 Accumulators structurally combined with charging apparatus circuits for charging H02J7/00
• CPC Class Codes: H01M 50/107 having curved cross-section, e.g. round or elliptic H01M50/103, H01M50/109, H01M50/11 take precedence
• CPC Class Codes: H01M 50/114 specially adapted for lead-acid cells
• CPC Class Codes: H01M 50/147 Lids or covers
• CPC Class Codes: H01M 50/213 adapted for cells having curved cross-section, e.g. round or elliptic H01M50/209, H01M50/216 take precedence
• CPC Class Codes: H01M 50/247 specially adapted for portable devices, e.g. mobile phones, computers, hand tools or pacemakers
• CPC Class Codes: H01M 50/271 Lids or covers for the racks or secondary casings
• CPC Class Codes: H01M 50/325 comprising deformable valve members, e.g. elastic or flexible valve members
• CPC Class Codes: H01M 6/10 with wound or folded electrodes
• 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

Abstract

An electrochemical cell case and method of manufacturing an electrochemical battery are provided. The cell case includes a main body that encloses a plurality of individual cells in separate, contiguous compartments. After the cells have been inserted into the compartments, the compartments are hermetically sealed. The compartments may be separately filled and vented, and the cell of each compartment receives end connectors such as rivet connectors. The elements are electrically interconnected, such as in a series configuration. A top cap attaches to the main body, and encloses the interconnected cell terminals. The top cap may also enclose other electronics, such as battery recharging circuitry or a temperature sensor. The top cap may be sized and shaped to mate with connectors on specific electrical devices, and may be removable so that another top cap may be installed for use with another device.

Claims

1. An electrochemical cell case, comprising a body having a plurality of compartments, each compartment to receive an electrochemical cell, said compartments being sealed from one another, each compartment having an upper portion and a lower portion and a pressure relief valve, and a first terminal hole through said body into said upper portion and a second terminal hole into said lower portion.

2. The electrochemical cell case of claim 1, wherein said body includes a first exterior surface, and further comprising a cap having a raised perimeter edge attached to said first exterior surface to define a space between said cap and said first exterior surface.

3. The electrochemical cell case of claim 2, wherein said cap is adapted for electrical communication between said electrochemical cells and an electrical device.

4. The electrochemical cell case of claim 3, wherein said cap is shaped to reversibly and physically connect with said electrical device.

5. The electrochemical cell case of claim 2, further including an electrical unit, said electrical unit being housed in said space and being selected from the group consisting of a recharger for recharging said electrochemical cells and a temperature sensor for monitoring the temperature within said body.

6. An electrochemical cell case, comprising:

(a) a body having a plurality of compartments, each compartment including a sidewall and a cavity, said cavity at least partially defined by said sidewall and being adapted for receiving an electrochemical cell and having a first and second end, said compartments being sealed from one another and each compartment having a pressure relief valve;

(b) a first cover covering said first end of said cavities;

(c) a second cover covering said second end of said cavities; and

(d) a first and second terminal hole extending into each said cavity, wherein no more than one of said terminal holes is in said first cover and wherein no more than one of said terminal holes is in said second cover.

7. The electrochemical cell case of claim 6, wherein at least one of said first and second cover includes a sealable port for introducing electrolyte into said cavity.

8. The electrochemical cell case of claim 6, further including a cap attached to one of said first and second cover, said cap allowing for electrical communication between said electrochemical cells and an electrical device.

9. The electrochemical cell case of claim 8, wherein said cap is shaped to reversibly and physically connect with said electrical device.

10. The electrochemical cell case of claim 6, further including a first cap having a raised perimeter edge which is attached to said first cover to define a first space between said first cap and said first cover.

11. The electrochemical cell case of claim 10, further including a second cap having a raised perimeter edge which is attached to said second cover to define a second space between said second cap and said second cover.

12. The electrochemical cell case of claim 10, further including a layer of absorbent material disposed in said first space for absorbing fluid released into said first space.

13. The electrochemical cell case of claim 10, wherein said first cap includes at least one perforation to allow the release of pressure from said first space.

14. The electrochemical cell case of claim 11, wherein at least one of said first and second cap includes at least one terminal port for passage of an electrical terminal to outside said electrochemical cell case.

15. The electrochemical cell case of claim 11, further including an electrical unit, said electrical unit being housed in said first or second space and being selected from the group consisting of a recharger for recharging said electrochemical cells and a temperature sensor for monitoring the temperature within said body.

16. The electrochemical cell case of claim 6, wherein said compartments and cavities are substantially cylindrical in shape so as to receive substantially cylindrical electrochemical cells.

17. The electrochemical cell case of claim 16, wherein said electrochemical cell case includes at least three of said cylindrical compartments with their longitudinal axes parallel.

18. The electrochemical cell case of claim 16, wherein said electrochemical cell case includes exactly six cylindrical compartments positioned in two rows of three with their longitudinal axes parallel.

19. An electrochemical cell case, comprising:

(a) a body having a plurality of cavities, each of said cavities being adapted to receive an electrochemical cell and being sealed from one another, and each cavity having a pressure relief valve and a first and second end;

(b) a first cover to cover said first end;

(c) a second cover to cover said second end; and

(d) a cap attached to one of said first and second cover, said cap being shaped to physically connect with an electrical device and allowing for electrical communication between said electrochemical cells and said electrical device.

20. The electrochemical cell case of claim 19, wherein said cap is shaped so it can be partially inserted within said electrical device.

21. The electrochemical cell case of claim 20, wherein said cap can be reversibly connected to said electrical device.

22. The electrochemical cell case of claim 19, further including an electrical unit, said electrical unit being housed in said cap and being selected from the group consisting of a recharger for recharging said electrochemical cells and a temperature sensor for monitoring the temperature within said body.

23. The electrochemical cell case of claim 19, wherein said cavities are substantially cylindrical in shape so as to receive substantially cylindrical electrochemical cells.

24. The electrochemical cell case of claim 23, wherein said electrochemical cell case includes at least three cylindrical cavities with their longitudinal axes parallel to one another.

25. The electrochemical cell case of claim 23, wherein said electrochemical cell case includes exactly six cylindrical cavities positioned in two rows of three with their longitudinal axes parallel.

26. A battery, comprising:

(a) a plurality of electrochemical cells; and

(b) an electrochemical cell case including a body having a plurality of compartments, each of said compartments being shaped to receive one of said electrochemical cells, said compartments being sealed from one another, and each compartment having an upper portion and a lower portion and a pressure relief valve; and

a first terminal hole through said body into said upper portion and a second terminal hole through said body into said lower portion.

27. The battery of claim 26, wherein said body includes a first exterior surface, and further comprising a cap having a raised perimeter edge attached to said first exterior surface to define a space between said cap and said first exterior surface, said cap being adapted for electrical communication between said electrochemical cells and an electrical device.

28. The battery of claim 27, wherein said cap is shaped to reversibly and physically connect with said electrical device.

29. The battery of claim 27, further including an electrical unit, said electrical unit being housed in said space and being selected from the group consisting of a recharger for recharging said electrochemical cells and a temperature sensor for monitoring the temperature within said body.

30. The battery of claim 26, wherein said electrochemical cells include a positive plate, a negative plate and a separator disposed therebetween, said positive plate, negative plate and separator being spirally wound together.

31. The battery of claim 26, wherein said electrochemical cells include a positive plate, a negative plate and a separator disposed therebetween, said positive plate, negative plate and separator being arranged in parallel stacks.

32. The battery of claim 30, wherein at least one of said positive and negative plate is less than 0.01 inches thick.

33. The battery of claim 31, wherein at least one of said positive and negative plate is less than 0.01 inches thick.

34. The battery of claim 30, wherein said positive and negative plate include a metal film sandwiched between layers of electrochemically active paste and wherein said film of at least one of said positive and negative plate is substantially non-perforated.

35. The battery of claim 31, wherein said positive and negative plate include a metal film sandwiched between layers of electrochemically active paste and wherein said film of at least one of said positive and negative plate is substantially non-perforated.

36. A battery, comprising:

(a) a plurality of electrochemical cells; and

(b) an electrochemical cell case including;

(i) a body having a plurality of compartments, each compartment including a sidewall and a cavity, said cavity at least partially defined by said sidewall and being adapted for receiving one of said electrochemical cells and having a first and second end, said compartments being sealed from one another and each compartment having a pressure relief valve;

(ii) a first cover covering said first end of said cavities;

(iii) a second cover covering said second end of said cavities; and

(iii) a first and second terminal hole extending into each said cavity,

wherein no more than one of said terminal holes is in said first cover and wherein no more than one of said terminal holes is in said second cover.

37. The battery of claim 36, further comprising a cap attached to one of said first and second cover, said cap allowing for electrical communication between said electrochemical cells and an electrical device and being shaped to reversibly and physically connect with said electrical device.

38. The battery of claim 36, further including a first cap having a raised perimeter edge attached to said first cover to define a first space between said first cap and said first cover.

39. The battery of claim 38, further including a second cap having a raised perimeter edge which is attached to said second cover to define a second space between said second cap and said second cover.

40. The battery of claim 38, further including a layer of absorbent material disposed in said first space for absorbing fluid released into said first space.

41. The battery of claim 39, further including an electrical unit, said electrical unit being housed in said first or second space and being selected from the group consisting of a recharger for recharging said electrochemical cells and a temperature sensor for monitoring the temperature within said body.

42. The battery of claim 36, wherein said compartments and cavities are substantially cylindrical in shape so as to receive substantially cylindrical electrochemical cells.

43. The battery of claim 42, wherein said electrochemical cell case includes at least three of said cylindrical compartments with their longitudinal axes parallel.

44. The battery of claim 42, wherein said case includes exactly six cylindrical compartments positioned in two rows of three with their longitudinal axes parallel.

45. The battery of claim 36, wherein said electrochemical cells include a positive plate, a negative plate and a separator disposed therebetween, said positive plate, negative plate and separator being spirally wound together.

46. The battery of claim 36, wherein said electrochemical cells include a positive plate, a negative plate and a separator disposed therebetween, said positive plate, negative plate and separator being arranged in parallel stacks.

47. The battery of claim 45, wherein at least one of said positive and negative plate is less than 0.01 inches thick.

48. The battery of claim 46, wherein at least one of said positive and negative plate is less than 0.01 inches thick.

49. The battery of claim 45, wherein said positive and negative plate include a metal film sandwiched between layers of electrochemically active paste and wherein said film of at least one of said positive and negative plate is substantially non-perforated.

50. The battery of claim 46, wherein said positive and negative plate include a metal film sandwiched between layers of electrochemically active paste and wherein said film of at least one of said positive and negative plate is substantially non-perforated.

51. A battery, comprising:

(a) a plurality of electrochemical cells; and

(b) an electrochemical case including;

(i) a body having a plurality of cavities, each of said cavities being adapted to receive one of said electrochemical cells and being sealed from one another, and each cavity having a pressure relief valve and a first and second end;

(ii) a first cover to cover said first end;

(iii) a second cover to cover said second end; and

(iv) a cap attached to one of said first and second cover, said cap being shaped to physically connect with an electrical device and allowing for electrical communication between said electrochemical cells and said electrical device.

52. The battery of claim 51, wherein said cap is shaped so it can be partially inserted within said electrical device.

53. The battery of claim 52, wherein said cap can be reversibly connected to said electrical device.

54. The battery of claim 51, further including an electrical unit, said electrical unit being housed in said cap and being selected from the group consisting of a recharger for recharging said electrochemical cells and a temperature sensor for monitoring the temperature within said body.

55. The battery of claim 51, wherein said cavities are substantially cylindrical in shape so as to receive substantially cylindrical electrochemical cells.

56. The battery of claim 55, wherein said electrochemical cell case includes at least three cylindrical cavities with their longitudinal axes parallel to one another.

57. The battery of claim 55, wherein said case includes exactly six cylindrical cavities positioned in two rows of three with their longitudinal axes parallel.

58. The battery of claim 51, wherein said electrochemical cells include a positive plate, a negative plate and a separator disposed therebetween, said positive plate, negative plate and separator being spirally wound together.

59. The battery of claim 51, wherein said electrochemical cells include a positive plate, a negative plate and a separator disposed therebetween, said positive plate, negative plate and separator being arranged in parallel stacks.

60. The battery of claim 58, wherein at least one of said positive and negative plate is less than 0.01 inches thick.

61. The battery of claim 59, wherein at least one of said positive and negative plate is less than 0.01 inches thick.

62. The battery of claim 58, wherein said positive and negative plate include a metal film sandwiched between layers of electrochemically active paste and wherein said film of at least one of said positive and negative plate is substantially non-perforated.

63. The battery of claim 59, wherein said positive and negative plate include a metal film sandwiched between layers of electrochemically active paste and wherein said film of at least one of said positive and negative plate is substantially non-perforated.