Appatraus and method for assembling a flexible battery that is electrolyte-tight

• US 20020106555A1
• Filed: 02/08/2001
• Published: 08/08/2002
• Est. Priority Date: 02/08/2001
• Status: Active Grant

• Current Assignee: Energizer Brands, LLC (Energizer Holdings, Inc.)
• Original Assignee: Eveready Battery Company Incorporated (Energizer Holdings, Inc.)
• Inventors: Langan, Richard A.
• Granted Patent: US 6,676,714 B2
• Time in Patent Office: Days
• US Class Current: 429/127
• CPC Class Codes: H01M 50/105 Pouches or flexible bags
• CPC Class Codes: H01M 50/119 Metals
• CPC Class Codes: H01M 50/121 Organic material
• CPC Class Codes: H01M 50/124 having a layered structure
• CPC Class Codes: H01M 50/129 with two or more layers of only organic material
• CPC Class Codes: H01M 50/133 Thickness
• CPC Class Codes: H01M 50/618 Pressure control
• CPC Class Codes: H01M 50/627 Filling ports
• 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 29/53135 Storage cell or battery

Abstract

The invention provides for an apparatus and method for making a flexible battery that is electrolyte-tight by ensuring that electrolyte does not contact the unsealed portion of the battery enclosure when electrolyte is injected into the battery enclosure and before it is sealed. The apparatus for assembling a flexible battery comprises a support body adapted to support a battery enclosure having an electrode pouch and a fill opening located in an upper portion of the electrode pouch. The apparatus comprises a dispensing element having a discharge orifice that directs the flow of electrolyte inside the electrode pouch and away from the unsealed surfaces of the battery enclosure when the dispensing element is in the fill position. The method of assembling a pouch battery comprises arranging the battery enclosure so that the fill opening is located in an upper portion of the electrode pouch and dispensing the electrolyte into the electrode pouch.

Claims

1. Apparatus for assembling a flexible battery, the flexible battery comprising a battery enclosure comprising an electrode pouch and a fill opening that is open when electrolyte is introduced into the electrode pouch and thereafter sealed, the apparatus comprising:

a support body adapted to support the battery enclosure with the fill opening located in an upper portion of the electrode pouch; and

a dispensing element for introducing electrolyte into the battery enclosure, the dispensing element having a discharge orifice that directs the flow of electrolyte into the electrode pouch and away from the unsealed portion of the battery enclosure surrounding the fill opening.

2. The apparatus of claim 1 wherein the battery enclosure has opposing walls that are joined along at least a portion of the perimeter of the enclosure and wherein the support body supports the battery enclosure such that the joined walls are oriented vertically during the introduction of electrolyte into the electrode pouch.

3. The apparatus of claim 2 wherein the support body supports the battery enclosure such that the fill opening in the upper portion of the electrode pouch is located above a predetermined electrolyte fill level.

4. The apparatus of claim 3 wherein the apparatus further comprises a vacuum port and a vacuum chamber surrounding the battery enclosure that imparts reduced pressure within the chamber.

5. The apparatus of claim 2 wherein the fill opening is formed by an opening in the perimeter between the joined walls.

6. The apparatus of claim 5 wherein gravity causes the electrolyte to flow in a downward direction during the introduction of electrolyte into the electrode pouch.

7. The apparatus of claim 6 wherein the support body supports the battery enclosure such that the fill opening is located vertically above the electrode assembly.

8. The apparatus of claim 7 wherein the dispensing element moves vertically between a retracted position and a fill position, and the dispensing element is located vertically above the electrode assembly when the dispensing element is in the fill position.

9. The apparatus of claim 8 wherein the dispensing element is sized to move from the retracted position to the fill position without contacting the portion of the battery enclosure surrounding the fill opening.

10. The apparatus of claim 2 wherein the battery enclosure further comprises a gas pouch and a connecting channel between the gas pouch and the electrode pouch.

11. The apparatus of claim 10 wherein the dispensing element extends through the gas pouch and the connecting channel when moving from the retracted position to the fill position.

12. The apparatus of claim 1 further comprising a seal assembly that closes the fill opening.

13. The apparatus of claim 1 further comprising:

a control system operably connected to the dispensing element or the electrode pouch, or both, and,

a programmable platform for imparting relative registration positioning of the dispensing element relative to the fill opening.

14. The apparatus of claim 1 further comprising:

an electrolyte source in fluid communication with the dispensing element;

a pressure source that exerts pressure on the electrolyte source and causes the electrolyte to flow to the dispensing element; and

a control system operably connected to the electrolyte source or the pressure source, or both, to regulate the amount of electrolyte that is discharged into the electrode pouch.

15. The apparatus of claim 1 further comprising a suction element to remove electrolyte from the discharge orifice of the dispensing element.

16. The apparatus of claim 2 wherein the electrode pouch comprises an electrode assembly having an anode tab and a cathode tab extending from the interior of the electrode pouch to the exterior of the electrode pouch between the opposing walls at a location other than the fill opening.

18. The method of claim 17 wherein the battery enclosure has opposing walls that are joined along at least a portion of the perimeter of the enclosure, said method further comprising supporting the battery enclosure such that the joined walls are oriented vertically during the introduction of electrolyte into the electrode pouch.

19. The method of claim 18, further comprising providing a vacuum chamber surrounding the battery enclosure and applying a vacuum within said chamber during the introduction of electrolyte.

20. The method of claim 18, further comprising forming the electrolyte fill opening from an opening in the joined perimeter of the enclosure between the opposing walls.

21. The method of claim 20 further comprising sealing the fill opening following the introduction of electrolyte into the electrode pouch.

22. The method of claim 21 further comprising providing an anode tab and a cathode tab extending from the interior of the electrode pouch to the exterior of the electrode pouch between the opposing walls at a location other than the fill opening.

23. The method of claim 21, further comprising providing a gas pouch in fluid communication with the electrode pouch.

24. A battery made by the method of claim 18.

17. A method for assembling a flexible battery from a battery enclosure comprising an electrode pouch comprising an electrode assembly and an electrolyte fill opening, the method comprising:

arranging the battery enclosure so that the fill opening is in an upper portion of the battery enclosure, and

introducing electrolyte into the electrode pouch through the fill opening.

25. A battery comprising flexible opposing walls joined together about at least a portion of the perimeter of said battery, a sealed electrolyte fill opening, and one or more contacts extending from the interior of the battery to the exterior of the battery between the opposing walls at a location other than the fill opening location.