Battery

• US 6,235,422 B1
• Filed: 05/28/1999
• Issued: 05/22/2001
• Est. Priority Date: 05/28/1999
• Status: Expired due to Term

• Current Assignee: Duracell U.S. Operations, Inc. (Berkshire Hathaway Incorporated)
• Original Assignee: Gillette Company (The Procter & Gamble Company)
• Inventors: Sargeant, Sean A., Woodnorth, Douglas, Kaplan, Alexander, Vu, Viet H.
• Primary Examiner(s): CHANEY, CAROL DIANE
• Application Number:
  US09/321,930
• Time in Patent Office: 725 Days
• Field of Search: 291/50--61, 291/64--69, 291/71, 291/74, 291/85
• US Class Current: 429/161
• CPC Class Codes: H01M 10/283 Cells or batteries with two cup-shaped or cylindrical collectors H01M10/281 takes precedence
• CPC Class Codes: H01M 50/528 Fixed electrical connections, i.e. not intended for disconnection
• CPC Class Codes: H01M 50/543 Terminals
• CPC Class Codes: H01M 50/548 on opposite sides of the cell
• CPC Class Codes: H01M 6/06 Dry cells, i.e. cells wherein the electrolyte is rendered non-fluid
• CPC Class Codes: H01M 6/42 Grouping of primary cells into batteries H01M6/40 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

Abstract

A battery includes a housing, a first electrode, a second electrode having a plurality of cavities within the first electrode, a separator between each cavity and the first electrode, a seal positioned above the first electrode and the cavity, and a current collector. The current collector includes a member passing through the seal, a prong extending into each cavity, and a branch member connecting each prong to the member beneath the seal.

Claims

1. A battery comprising:

a housing;

a first electrode within the housing;

a second electrode comprising a plurality of cavities including an electrode-active material and surrounded, in cross-section, by the first electrode;

a separator between each of the cavities and the first electrode;

a seal that prevents leakage positioned above the first electrode and the cavities; and

a current collector comprising

a member passing through the seal,

a plurality of prongs, each of the prongs extending into one of the cavities, and

a plurality of branch members, each of the branch members connecting at least one of the prongs to the member beneath the seal.

2. The battery of claim 1, further comprising a second seal positioned between the branch members and the first electrode.

3. The battery of claim 1, wherein the second electrode consists of two cavities including the electrode-active material.

4. The battery of claim 3, wherein the cavities are D-shaped.

5. The battery of claim 1, wherein the second electrode comprises three cavities including the electrode-active material.

6. The battery of claim 1, wherein the second electrode comprises four cavities including the electrode-active material.

7. The battery of claim 1, wherein the first electrode is a cathode.

8. The battery of claim 7, wherein the cathode comprises manganese dioxide.

9. The battery of claim 8, wherein the second electrode is an anode comprising zinc.

10. The battery of claim 7, wherein the second electrode is an anode comprising zinc.

11. The battery of claim 1, wherein each of the cavities is triangle-shaped.

12. The battery of claim 1, wherein each of the cavities is cylindrically shaped.

13. The battery of claim 1, wherein the battery is a AA battery.

14. The battery of claim 1, wherein the battery is a AAA battery.

15. The battery of claim 1, wherein the battery is a AAAA battery.

16. The battery of claim 1, wherein the battery is a C battery.

17. The battery of claim 1, wherein the battery is a D battery.

18. The battery of claims 1 or 2, wherein the housing is cylindrical.

19. The battery of claim 1, wherein the plurality of branch members connect to the vertical member through a lock that snaps.

21. The battery of claim 19, further comprising a second seal positioned between the branch members and the first electrode.

20. A battery comprising:

a housing;

a first electrode within the housing;

a second electrode surrounded, in cross-section, by the first electrode;

a separator between the first electrode and the second electrode;

a seal positioned above the first electrode and the second electrode; and

a current collector comprising

a member passing through the seal,

a plurality of prongs

a plurality of branch members, each of the branch members connecting a prong to the member beneath the seal.

22. The battery of claim 20, wherein the first electrode is a cathode.

23. The battery of claim 22, wherein the cathode comprises manganese dioxide.

24. The battery of claim 23, wherein the second electrode is an anode comprising zinc.

25. The battery of claim 20, wherein the second electrode is an anode.

26. The battery of claim 20, wherein the battery is selected from the group consisting of AA, AAA, AAAA, C, and D batteries.

27. The battery of claim 20, wherein the housing is cylindrical.

28. The battery of claim 20, wherein the plurality of branch members connect to the vertical member through a lock that snaps.

29. A battery comprising:

a housing;

a first electrode within the housing;

a second electrode comprising a plurality of cavities, including an electrode-active material, within the first electrode;

a separator between each of the cavities and the first electrode;

a first seal that prevents leakage positioned above the first electrode and the cavities;

a second seal positioned between the branch members and the first electrode; and

a current collector comprising

a member passing through the first seal,

a plurality of prongs, each of the prongs extending into one of the cavities, and

a plurality of branch members, each of the branch members connecting at least one of the prongs to the member beneath the first seal.

30. The battery of claim 29, wherein the first electrode is a cathode.

31. The battery of claim 30, wherein the cathode comprises manganese dioxide.

32. The battery of claims 29, 30, or 31, wherein the second electrode includes zinc as the active electrode material.

33. A battery comprising

a housing;

a cathode comprising a plurality of cavities, including an anode-active material comprising zinc, within the cathode;

a separator between each of the cavities and the cathode;

a seal that prevents leakage positioned above the cathode and the cavities; and

a current collector comprising

a member passing through the seal,

a plurality of prongs, each of the prongs extending into one of the cavities, and

a plurality of branch members, each of the branch members connecting at least one of the prongs to the member beneath the seal.

34. The battery of claim 33, wherein the cathode comprises manganese dioxide.

35. A battery comprising

a housing;

a cathode comprising manganese dioxide within the housing;

an anode, comprising a plurality of cavities within the cathode including an anode-active material;

a separator between each of the cavities and the cathode;

a seal that prevents leakage positioned above the cathode and the cavities; and

a current collector comprising

a member passing through the seal,

a plurality of prongs, each of the prongs extending into one of the cavities, and

a plurality of branch members, each of the branch members connecting at least one of the prongs to the member beneath the seal.