Electric storage battery construction and method of manufacture

• US 7,601,461 B2
• Filed: 09/17/2003
• Issued: 10/13/2009
• Est. Priority Date: 01/15/2002
• Status: Active Grant

• Current Assignee: Quallion, LLC (EnerSys)
• Original Assignee: Qualllion LLC
• Inventors: Tsukamoto, Hisashi, Skinlo, David M., Zolotnik, Vladimir, Parkhouse, Leon, Szyszkowski, Andrew
• Primary Examiner(s): Ryan; Patrick
• Assistant Examiner(s): LEE, CYNTHIA K
• Application Number:
  US10/666,790
• Publication Number:
  US 20040058236A1
• Time in Patent Office: 2,218 Days
• Field of Search: 429/51, 429/81, 429/94
• US Class Current: 429/182
• CPC Class Codes: H01M 10/0431 Cells with wound or folded electrodes H01M10/045 takes precedence
• 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 50/119 Metals
• CPC Class Codes: H01M 50/154 Lid or cover comprising an axial bore for receiving a central current collector
• CPC Class Codes: H01M 50/545 formed by the casing of the cells cup shaped terminals adapted for cells having curved cross-section H01M50/56
• CPC Class Codes: H01M 50/548 on opposite sides of the cell
• CPC Class Codes: H01M 50/559 Terminals adapted for cells having curved cross-section, e.g. round, elliptic or button cells H01M50/553 takes precedence
• 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
• CPC Class Codes: Y10T 29/49108 Electric battery cell making
• CPC Class Codes: Y10T 29/4911 including sealing
• CPC Class Codes: Y10T 29/49112 including laminating of indefinite length material
• CPC Class Codes: Y10T 29/49115 including coating or impregnating

Abstract

An electric storage battery and method of manufacture thereof characterized by a feedthrough pin which is internally directly physically and electrically connected to an inner end of a positive electrode substrate. A C-shaped mandrel extends around the pin and substrate end enabling the pin/mandrel to be used during the manufacturing process as an arbor to facilitate winding layers of a spiral jellyroll electrode assembly. The pin additionally extends from the battery case and in the final product constitutes one of the battery terminals with the battery case comprising the other terminal. Active material is removed from both sides of the outer end of the negative electrode in the jellyroll to allow room for adhesive tape to secure the jellyroll. The electrolyte is injected through the open end of the case after the endcap is welded to the negative electrode but before sealing the endcap to the case. The electrolyte is preferably injected through the C-shaped mandrel to facilitate and speed filling.

Claims

1. An electric storage battery, comprising:

a case hermetically sealed by a first end cap and a second end cap, wherein the case excludes fill holes and wherein the first end cap excludes fill holes and the second end cap excludes fill holes;

an electrically conductive terminal pin extending through the first end cap and electrically insulated from the case;

an electrode assembly disposed within the case,

the electrode assembly includes an electrode in electrical communication with the pin and an electrode electrically insulated from the pin,

the electrode assembly includes a mandrel mounted on the pin such that the electrodes are wound around the pin and the mandrel, and

a portion of the electrode that is in electrical communication with the pin is positioned between the mandrel and the pin; and

a flexible conductive tab providing electrical communication between the second end cap and the electrode that is electrically insulated from the pin.

2. The battery of claim 1, wherein the tab extends from a first location adjacent to the case past a center point of the second end cap to a second location where the tab is electrically connected to the second end cap.

3. The battery of claim 2, wherein a weld connects a flat portion of the tab to an inner face of the second end cap.

4. The battery of claim 2, wherein the tab is not connected to the second end cap continuously over a distance extending from the first location to the second location.

5. The battery of claim 2, wherein the portion of the second end cap adjacent to the tab has a radius and the tab is positioned adjacent to the second end cap without being connected to the second end cap for a distance that is longer than the radius.

6. The battery of claim 1, wherein the electrodes are electrode strips wound around the pin so as to form a spiral role on the pin.

7. The battery of claim 6, wherein the spiral role includes at least one separator separating the electrodes.

8. The battery of claim 1, wherein the mandrel includes a longitudinal slot;

and wherein

the electrode in electrical communication with the pin extends through the mandrel slot.

9. The battery of claim 1, wherein the mandrel has a channel through which electrolyte can be injected.

10. The battery of claim 1, wherein the electrode in electrical communication with the pin includes active material positioned on a substrate, the substrate being positioned between the mandrel and the pin without the active material being positioned between the mandrel and the pin.

11. The battery of claim 1, wherein the mandrel is crimped to the pin.

12. The battery of claim 1, wherein a weld attaches the mandrel to the pin.

13. The battery of claim 1, wherein the mandrel includes titanium or an alloy of titanium.

14. The battery of claim 1, wherein the mandrel includes a tube.

15. The battery of claim 14, wherein the pin is positioned in an interior of the tube.

16. The battery of claim 1, wherein the mandrel has a c-shaped cross-section.

17. The battery of claim 1, wherein the mandrel is fitted around the pin such that the electrodes are wound around the pin and the mandrel.

18. The battery of claim 1, wherein the mandrel is a reinforcing mandrel.

19. The battery of claim 1, wherein at least one weld directly connects the electrode that is in electrical communication with the pin to the pin.

20. The battery of claim 1, wherein the pin includes an alloy of PtIr.

21. The battery of claim 1, wherein the first end cap includes

an electrical insulator,

the pin extends through the electrical insulator, and

the pin is hermetically sealed to the electrical insulator.

22. The battery of claim 1, wherein the case is electrically conducting.

23. An electric storage battery comprising:

a case hermetically sealed by a first end cap and a second end cap, wherein the case excludes fill holes and wherein the first end cap excludes fill holes and the second end cap excludes fill holes;

an electrically conductive terminal pin extending through the first end cap and electrically insulated from the case;

an electrode assembly disposed within the case,

the electrode assembly includes an electrode in electrical communication with the pin and an electrode electrically insulated from the pin,

the electrode assembly includes a mandrel mounted on the pin such that the electrodes are wound around the pin and the mandrel, and

a weld attaches the mandrel to the pin; and

a flexible conductive tab providing electrical communication between the second end cap and the electrode that is electrically insulated from the pin.

24. The battery of claim 23, wherein the tab extends from a first location adjacent to the case past a center point of the second end cap to a second location where the tab is electrically connected to the second end cap.

25. The battery of claim 24, wherein a weld connects a flat portion of the tab to an inner face of the second end cap.

26. The battery of claim 24, wherein the tab is not connected to the second end cap continuously over a distance extending from the first location to the second location.

27. The battery of claim 24, wherein the portion of the second end cap adjacent to the tab has a radius and the tab is positioned adjacent to the second end cap without being connected to the second end cap for a distance that is longer than the radius.

28. The battery of claim 23, wherein the electrodes are electrode strips wound around the pin so as to form a spiral role on the pin.

29. The battery of claim 28, wherein the spiral role includes at least one separator separating the electrodes.

30. The battery of claim 23, wherein the mandrel includes a longitudinal slot;

and wherein

the electrode in electrical communication with the pin extends through the mandrel slot.

31. The battery of claim 23, wherein the mandrel has a channel through which electrolyte can be injected.

32. The battery of claim 23, wherein the electrode that is in electrical communication with the pin includes active material positioned on a substrate, the substrate being positioned between the mandrel and the pin without the active material being positioned between the mandrel and the pin.

33. The battery of claim 23, wherein the mandrel is crimped to the pin.

34. The battery of claim 23, wherein the mandrel includes titanium or an alloy of titanium.

35. The battery of claim 23, wherein the mandrel includes a tube.

36. The battery of claim 35, wherein the pin is positioned in an interior of the tube.

38. The battery of claim 23, wherein at least one weld directly connects the electrode that is in electrical communication with the pin to the pin.

39. The battery of claim 23, wherein the pin includes an alloy of PtIr.

40. The battery of claim 23, wherein the first end cap includes

an electrical insulator,

the pin extends through the electrical insulator, and

the pin is hermetically sealed to the electrical insulator.

41. The battery of claim 23, wherein the case is electrically conducting.

37. The battery of 23, wherein the mandrel has a c-shaped cross-section.