Prismatic battery

• US 8,883,345 B2
• Filed: 12/23/2008
• Issued: 11/11/2014
• Est. Priority Date: 12/28/2007
• Status: Active Grant

• Current Assignee: Encell Technology, Inc
• Original Assignee: Encell Technology, Inc
• Inventors: Ogg, Randy
• Primary Examiner(s): HAN, KWANG S
• Application Number:
  US12/342,542
• Publication Number:
  US 20090173582A1
• Time in Patent Office: 2,149 Days
• Field of Search: None
• US Class Current: 429/209
• CPC Class Codes: H01M 10/0413 Large-sized flat cells or batteries for motive or stationary systems with plate-like electrodes
• CPC Class Codes: H01M 10/281 Large cells or batteries with stacks of plate-like electrodes
• CPC Class Codes: H01M 4/0404 by coating on electrode collectors
• CPC Class Codes: H01M 4/043 involving compressing or compaction
• CPC Class Codes: H01M 4/244 Zinc electrodes
• CPC Class Codes: H01M 4/26 Processes of manufacture
• CPC Class Codes: H01M 4/50 of manganese
• CPC Class Codes: H01M 4/661 Metal or alloys, e.g. alloy coatings H01M4/669 take precedence
• CPC Class Codes: H01M 4/70 characterised by shape or form
• CPC Class Codes: H01M 4/808 Foamed, spongy materials
• CPC Class Codes: H01M 50/531 Electrode connections inside a battery casing
• CPC Class Codes: H01M 50/553 Terminals adapted for prismatic, pouch or rectangular cells
• CPC Class Codes: H02J 7/35 with light sensitive cells
• CPC Class Codes: H02J 9/06 with automatic change-over , e.g. UPS systems
• CPC Class Codes: Y02B 10/70 Hybrid systems, e.g. uninterruptible or back-up power supplies integrating renewable energies
• 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 29/49115 including coating or impregnating

Abstract

Provided is a prismatic battery comprising stacked positive electrode plates, negative electrode plates and separator layers therebetween. The positive and negative electrode plates extend beyond a periphery of the electrode stack. The positive electrode plates are fused to form a positive current collector, and the negative electrode plates are fused to form a negative current collector. Both the positive and negative electrode plates comprise a metal foam and are compressed between about 42 and 45% of the original thickness.

Claims

1. A rechargeable prismatic battery comprising:

an electrode stack comprised of positive electrode plates and negative electrode plates, wherein;

the positive electrode plates each comprise;

manganese dispersed throughout a compressed metal foam comprising a polymer binder; and

with the positive electrode plates extending beyond a periphery of the electrode stack, and with the positive electrode plates arranged such that the positive electrode plates are aligned with one another and are fused; and

the negative electrode plates each comprise;

zinc dispersed throughout a compressed metal foam comprising a polymer binder; and

with the negative electrode plates extending beyond a periphery of the electrode stack, and with the negative electrode plates arranged such that the negative electrode plates are aligned with one another and are fused, and

with both the positive electrode plates and the negative electrode plates compressed between about 42 and 45% of the original thickness.

2. The rechargeable prismatic battery of claim 1, wherein the fused positive electrode plates are connected to a positive terminal.

3. The rechargeable prismatic battery of claim 1, wherein the fused negative electrode plates are connected to a negative terminal.

4. The rechargeable prismatic battery of claim 1, wherein the periphery of the electrode stack of positive electrode plates comprises a finite number of sides, and further wherein the positive electrode plates are fused to form positive current collectors at multiple sides of the electrode stack.

5. The rechargeable prismatic battery of claim 4, wherein the positive current collectors are coextensive with the sides of the electrode stack.

6. The rechargeable prismatic battery of claim 1, wherein the periphery of the electrode stack of negative electrode plates comprises a finite number of sides, and further wherein the negative electrode plates are fused to form negative current collectors at multiple sides of the electrode stack.

7. The rechargeable prismatic battery of claim 6, wherein the positive current collectors are coextensive with the sides of the electrode stack.

8. The rechargeable prismatic battery of claim 1, wherein the periphery of the electrode stack of positive electrode plates comprises an even number of sides, and further wherein the positive electrode plates are fused to form positive current collectors at alternating sides of the electrode stack.

9. The rechargeable prismatic battery of claim 1, wherein the periphery of the electrode stack of negative electrode plates comprises an even number of sides, and further wherein the negative electrode plates are fused to form negative current collectors at alternating sides of the electrode stack.

10. The rechargeable prismatic battery of claim 1, wherein all of the positive electrode plates are of the same shape, and all of the negative electrode plates are of the same shape.

11. The rechargeable prismatic battery of claim 1, wherein all of the positive electrode plate extensions and all of the negative electrode plates are bent at the same angle.

12. The rechargeable prismatic battery of claim 1, wherein carboxy methylcellulose is contained in the compressed metal foam as a polymeric binder.

13. A prismatic battery comprising:

an electrode stack comprised of positive electrode plates, negative electrode plates, and separator layers therebetween, wherein;

the positive electrode plates extend beyond a periphery of the electrode stack, and the positive electrode plates are arranged such that the positive electrode plates are aligned with one another and are fused together to create a positive current collector, with the positive electrode plates comprising manganese dispersed throughout a compressed metal foam which is compressed between 42 and 45% of the original thickness; and

the negative electrode plates extend beyond a periphery of the electrode stack, and the negative electrode plates are arranged such that the negative electrode plates are aligned with one another and are fused together to create a negative current collector, with the negative electrode plates comprising zinc dispersed throughout a compressed metal foam which is compressed between about 42 and 45% of the original thickness.

14. The prismatic battery of claim 13, wherein the positive current collector is connected to a positive terminal.

15. The prismatic battery of claim 13, wherein the negative current collector is connected to a negative terminal.

16. The prismatic battery of claim 13, wherein the periphery of the electrode stack of positive electrode plates comprises a finite number of sides, and further wherein the positive electrode plates are fused to form positive current collectors at multiple sides of the electrode stack.

17. The prismatic battery of claim 16, wherein the positive current collectors are coextensive with the sides of the electrode stack.

18. The prismatic battery of claim 13, wherein the periphery of the electrode stack of negative electrode plates comprises a finite number of sides, and further wherein the negative electrode plates are fused to form negative current collectors at multiple sides of the electrode stack.

19. The prismatic battery of claim 18, wherein the positive current collectors are coextensive with the sides of the electrode stack.

20. The prismatic battery of claim 13, wherein the periphery of the electrode stack of positive electrode plates comprises an even number of sides, and further wherein the positive electrode plates are fused to form positive current collectors at alternating sides of the electrode stack.

21. The prismatic battery of claim 13, wherein the periphery of the electrode stack of negative electrode plates comprises an even number of sides, and further wherein the negative electrode plates are fused to form negative current collectors at alternating sides of the electrode stack.

22. The prismatic battery of claim 13, wherein all of the positive electrode plates are of the same shape, and all of the negative electrode plates are of the same shape.

23. The prismatic battery of claim 13, wherein all of the positive electrode plates and all of the negative electrode plates are bent at the same angle.