Method of connecting electric leads to battery tabs

• US 6,641,027 B2
• Filed: 12/18/2001
• Issued: 11/04/2003
• Est. Priority Date: 12/18/2001
• Status: Expired due to Fees

• Current Assignee: NGK Spark PLUG Company Limited
• Original Assignee: NGK Spark PLUG Company Limited
• Inventors: Daroux, Mark L., Xing, Xuekun, OʼConnell, Ronald V., Thomas, Shawn E.
• Primary Examiner(s): Elve, M. Alexandra
• Assistant Examiner(s): Tran, Len
• Application Number:
  US10/023,511
• Publication Number:
  US 20030111512A1
• Time in Patent Office: 686 Days
• Field of Search: 228/110.1, 228/1.1, 228/212, 228/213, 228/44.7, 228/156, 228/73.1, 228/73.2, 228/58, 429/211, 429/161, 429/178, 429/127
• US Class Current: 228/110.1
• CPC Class Codes: B23K 20/10 making use of vibrations, e.g. ultrasonic welding
• CPC Class Codes: H01M 50/533 characterised by the shape of the leads or tabs
• CPC Class Codes: H01M 50/534 characterised by the material of the leads or tabs
• CPC Class Codes: H01M 50/536 characterised by the method of fixing the leads to the electrodes, e.g. by welding
• CPC Class Codes: H01R 43/0207 Ultrasonic-, H.F.-, cold- or impact welding
• CPC Class Codes: Y02E 60/10 Energy storage using batteries

Abstract

A method of connecting a generally flat battery lead to at least one flat current collector of a polymer battery, comprising the steps of: bending a generally planar lead about at least one generally planar current collector tab to form a layered area, wherein at least one planar tab is disposed between planar portions of the lead with the lead wrapped around one edge of at least one tab; clamping the layered area between two weld fixtures of an ultrasonic welder; and vibrating the weld fixtures to ultrasonically weld together the battery lead and at least one current collector tab.

Claims

1. A method of connecting a generally flat battery lead to at least one flat current collector of a polymer battery, comprising the steps of:

bending a generally planar lead about at least one generally planar current collector tab to form a layered area, wherein said at least one planar tab is disposed between planar portions of said lead with said lead wrapped around one edge of said at least one tab and with said lead disposed on opposite sides of said at least one tab;

clamping said layered area between two weld fixtures of an ultrasonic welder;

vibrating said weld fixtures to ultrasonically weld together said battery lead and said at least one current collector tab to form a multi-layered weld area comprised of said at least one tab and said planar portions of said lead; and

trimming said weld area by removing said one edge of said at least one tab.

2. A method as defined in claim 1, wherein said weld area has a round edge projecting from said current collector.

3. A method as defined in claim 1, wherein said current collector is a metal mesh and said lead is a copper strip.

4. A method as defined in claim 1, wherein said lead is bent to be aligned with said at least one current collector tab.

5. A method as defined in claim 4, further comprising the step of packaging said current collector within a flexible package wherein said weld area is disposed within said package and said lead extends through said package.