U.S. patent application number 09/902871 was filed with the patent office on 2003-01-16 for bipolar electrochemical battery of stacked wafer cells.
Invention is credited to Klein, Martin G., Plivelich, Robert, Ralston, Paula.
Application Number | 20030013015 09/902871 |
Document ID | / |
Family ID | 25416530 |
Filed Date | 2003-01-16 |
United States Patent
Application |
20030013015 |
Kind Code |
A1 |
Klein, Martin G. ; et
al. |
January 16, 2003 |
BIPOLAR ELECTROCHEMICAL BATTERY OF STACKED WAFER CELLS
Abstract
The bipolar electrochemical battery of the invention comprises:
a stack of at least two electrochemical cells electrically arranged
in series with the positive face of each cell contacting the
negative face of an adjacent cell, wherein each of the cells
comprises (a) a negative electrode; (b) a positive electrode; (c) a
separator between the electrodes, wherein the separator includes an
electrolyte; (d) a first electrically conductive lamination
comprising a first inner metal layer and a first polymeric outer
layer, said first polymeric outer layer having at least one
perforation therein to expose the first inner metal layer, said
first electrically conductive lamination being in electrical
contact with the outer face of the negative electrode; and (e) a
second electrically conductive lamination comprising a second inner
metal layer and a second polymeric outer layer, said second
polymeric outer layer having at least one perforation therein to
expose the second inner metal layer, said second electrically
conductive lamination being in electrical contact with the outer
face of the positive electrode; wherein the first and second
laminations are sealed peripherally to each other to form an
enclosure including the electrodes, the separator and the
electrolyte.
Inventors: |
Klein, Martin G.;
(Brookfield, CT) ; Ralston, Paula; (Danbury,
CT) ; Plivelich, Robert; (Waterbury, CT) |
Correspondence
Address: |
KENYON & KENYON
ONE BROADWAY
NEW YORK
NY
10004
US
|
Family ID: |
25416530 |
Appl. No.: |
09/902871 |
Filed: |
July 11, 2001 |
Current U.S.
Class: |
429/210 ;
429/185; 429/246; 429/66 |
Current CPC
Class: |
Y02P 70/50 20151101;
H01M 50/10 20210101; H01M 10/0418 20130101; H01M 50/502 20210101;
H01M 10/0585 20130101; H01M 50/103 20210101; H01M 50/119 20210101;
H01M 50/121 20210101; H01M 4/667 20130101; H01M 10/345 20130101;
H01M 6/48 20130101; Y10T 29/49108 20150115; H01M 50/116 20210101;
H01M 6/42 20130101; H01M 50/124 20210101; Y02E 60/10 20130101; H01M
50/51 20210101; H01M 6/46 20130101; Y10T 29/4911 20150115; Y10T
29/49112 20150115 |
Class at
Publication: |
429/210 ;
429/185; 429/246; 429/66 |
International
Class: |
H01M 004/66; H01M
002/08; H01M 002/18 |
Goverment Interests
[0001] This invention was made with Government support under
contract NAS327787 awarded by the National Aeronautic and Space
Administration. The Government has certain rights in this
invention.
Claims
What is claimed is:
1. A bipolar electrochemical battery comprising: a stack of at
least two electrochemical cells electrically arranged in series
with the positive face of each cell contacting the negative face of
an adjacent cell, wherein each of the cells comprises (a) a
negative electrode; (b) a positive electrode; (c) a separator
between the electrodes, wherein the separator includes an
electrolyte; (d) a first electrically conductive lamination
comprising a first, inner metal layer and a first polymeric outer
layer, said first polymeric outer layer having at least one
perforation therein to expose the first, inner metal layer, said
first electrically conductive lamination being in electrical
contact with the outer face of the negative electrode; and (e) a
second electrically conductive lamination comprising a second,
inner metal layer and a second polymeric outer layer, said second
polymeric outer layer having at least one perforation therein to
expose the second, inner metal layer, said second electrically
conductive lamination being in electrical contact with the outer
face of the positive electrode; wherein the first and second
laminations are sealed peripherally to each other to form an
enclosure including the electrodes, the separator and the
electrolyte.
2. The bipolar electrochemical battery of claim 1 wherein said
electrodes, said separator and said first and second laminations
are each substantially flat.
3. The bipolar electrochemical battery of claim 1 wherein said
first and second inner metal layers are each a metal foil.
4. The bipolar electrochemical battery of claim 1 wherein the metal
layer is between about 0.0003 inches and about 0.005 inches
thick.
5. The bipolar electrochemical battery of claim 1 wherein the metal
layer is made of a metal selected from copper, aluminum, silver,
steel, lithium, nickel, metal plated materials and mixtures
thereof.
6. The bipolar electrochemical battery of claim 1 wherein said
first and second polymeric outer layers are each made of a
polymeric material selected from polypropylene, polyethylene,
polysofon, polyvinyl chloride and mixtures thereof.
7. The bipolar electrochemical battery of claim 6 wherein said
first and second polymeric outer layers are each a thin polymeric
film between about 0.001 inches and about 0.005 inches in
thickness.
8. The bipolar electrochemical battery of claim 1 wherein said
first and second polymeric outer layers each comprise a plurality
of perforations which are aligned with respect to each other to
create contacts points through which current can flow from cell to
cell.
9. The bipolar electrochemical battery of claim 1 wherein said
positive electrode comprises a material selected from oxygen,
magnesium, nickel, manganese, copper, cobalt, silver, lithium, an
oxide or hydroxide of nickel, an oxide or hydroxide of manganese,
an oxide or hydroxide of copper, an oxide or hydroxide of mercury,
an oxide or hydroxide of silver, an oxide or hydroxide of
magnesium, an oxide or hydroxide of lithium, an oxide or hydroxide
of cobalt and combinations thereof.
10. The bipolar electrochemical battery of claim 9 wherein said
positive electrode is an oxygen electrode or a nickel
electrode.
11. The bipolar electrochemical battery of claim 3 wherein at least
one metal foil and polymeric layer are bonded together with tar,
epoxy or rubber cement.
12. The bipolar electrochemical battery of claim 11 wherein said
nickel electrode is selected from a pasted foam, sintered and
plastic bonded nickel electrode.
13. The bipolar electrochemical battery of claim 1 wherein said
negative electrode comprises a material selected from cadmium,
iron, zinc, silver, lithium, carbon containing lithium, hydrogen
and mixtures thereof.
14. The bipolar electrochemical battery of claim 1 wherein said
negative electrode is a metal hydride electrode.
15. The bipolar electrochemical battery of claim 14 wherein the
metal hydride electrode is selected from the group consisting of a
nickel hydride electrode, a copper hydride electrode, a lithium
hydride electrode, an iron hydride electrode and mixtures
thereof.
16. The bipolar electrochemical battery of claim 1 wherein the
separator is porous.
17. The bipolar electrochemical battery of claim 1 wherein the
first and second polymeric outer layers are sealed to each other to
form the enclosure.
18. The bipolar electrochemical battery of claim 1 wherein a
conductive paste or cement is present between at least one of said
metal layers and said electrode with which it is in contact.
19. The bipolar electrochemical battery of claim 1 wherein said
stack of at least two electrochemical cells is contained in a
battery housing.
20. The bipolar electrochemical battery of claim 19 wherein a
pressure measuring device is included in said sealed battery
housing.
21. The bipolar electrochemical battery of claim 19 wherein each
electrochemical cell is completely sealed.
22. The bipolar electrochemical battery of claim 19 wherein a
conductive paste or cement is present between said cells.
23. The bipolar electrochemical battery of claim 19 wherein at
least one of the end cells of said stack of cells is in contact
with a metal foil contact, wherein said metal foil contact is
electrically connected to a battery terminal.
24. The bipolar electrochemical battery of claim 19 wherein said
stack of cells is held in compression.
25. The bipolar electrochemical battery of claim 19 wherein said
electrochemical cells include vent ports.
26. The bipolar electrochemical battery of claim 19 wherein a
plurality of cells are held in compression.
27. The bipolar electrochemical battery of claim 26 wherein the
cells are held in compression by a gas filled bladder.
28. The bipolar electrochemical battery of claim 19 wherein a metal
foil layer is placed between cells for thermal conduction.
29. The bipolar electrochemical batter of claim 19 wherein a cell
edge is extended for improved thermal contact to battery housing
walls.
30. The bipolar electrochemical battery of claim 19 wherein the
battery is contained in a housing with a honeycomb plate for
lightweight ridge containment of a cell stack.
31. The electrochemical wafer cell of claim 30 wherein the first
inner metal layer and the first polymeric outer layer are boned
together with tar, epoxy or rubber cement, and the second inner
metal layer and the second polymeric outer layer are bonded
together with tar, epoxy or rubber cement.
32. An electrochemical wafer cell comprising: (a) a negative
electrode; (b) a positive electrode; (c) a separator between the
electrodes, wherein the separator comprises an electrolyte; (d) a
first electrically conductive lamination comprising a first inner
metal layer and a first polymeric outer layer, said first polymeric
outer layer having at least one perforation therein to expose the
first inner metal layer, said first electrically conductive
lamination being in electrical contact with the outer face of the
negative electrode; and (e) a second electrically conductive
lamination comprising a second inner metal layer and a second
polymeric outer layer, said second polymeric outer layer having at
least one perforation therein to expose the second inner metal
layer, said second electrically conductive lamination being in
electrical contact with the outer face of the positive electrode;
wherein the first and second laminations are sealed peripherally to
each other to form an enclosure including the electrodes, the
separator and the electrolyte.
33. An assembly for containing contents of a wafer cell,
comprising: (a) a first electrically conductive lamination
comprising a first inner metal layer and a first polymeric outer
layer, said first polymeric outer layer having at least one
perforation therein to expose the first inner metal layer, said
first electrically conductive lamination capable of being in
electrical contact with a negative electrode; and (b) a second
electrically conductive lamination comprising a second inner metal
layer and a second polymeric outer layer, said second polymeric
outer layer having at least one perforation therein to expose the
second inner metal layer, said second electrically conductive
lamination capable being in electrical contact with a positive
electrode, wherein the first and second laminations are capable of
being sealed peripherally to each other to form an assembly for
containing the contents of a wafer cell.
34. A method of making a bipolar electrochemical battery comprising
the steps of: providing a stack of at least two electrochemical
cells electrically arranged in series with the positive face of
each cell contacting the negative face of an adjacent cell, wherein
each of the cells comprises (a) a negative electrode; (b) a
positive electrode; (c) a separator between the electrodes, wherein
the separator comprises an electrolyte; (d) a first electrically
conductive lamination comprising a first, inner metal layer and a
first polymeric outer layer, said first polymeric outer layer
having at least one perforation therein to expose the first, inner
metal layer, said first electrically conductive lamination being in
electrical contact with the outer face of the negative electrode;
and (e) a second electrically conductive lamination comprising a
second, inner metal layer and a second polymeric outer layer, said
second polymeric outer layer having at least one perforation
therein to expose the second, inner metal layer, said second
electrically conductive lamination being in electrical contact with
the outer face of the positive electrode; and sealing the first and
second laminations peripherally to each other to form an enclosure
including the electrodes, the separator and the electrolyte.
35. The electrochemical wafer cell of claim 32 wherein the cell has
extended edges.
Description
FIELD OF INVENTION
[0002] The present invention relates generally to packaging methods
and fabrication techniques for making electrochemical cells and
multi-cell batteries. In particular, the invention relates to
electrochemical cell constructions useful for primary and
rechargeable bipolar battery structures that have a high energy
storage capacity and efficient battery performance. More
specifically, this invention relates to electrochemical cells
including positive and negative electrode structures and methods of
making such cells that are capable of being stacked in a multi-cell
battery construction.
BACKGROUND OF THE INVENTION
[0003] Multi-cell batteries are typically constructed in a broad
range of electrochemical systems and are often packaged in
cylindrical or prismatic housings. Individual cells are connected
in series by conductive links to make the multi-cell batteries.
Such construction approaches provide for good sealing of the
individual cell compartments and for reliable operation. However,
such constructions allocate a large fraction of the multi-cell
battery's weight and volume to the packaging and, thus, do not make
full use of the energy storage capability of the active components
of the cell. For improving battery energy storage capacity on a
weight and volume basis, packaging approaches are sought that
reduce packaging weight and volume and that provide stable battery
performance and low internal resistance.
[0004] These objectives have led to the pursuit of a bipolar
construction in which an electrically conductive bipolar layer
serves as the electrical interconnection between adjacent cells, as
well as a partition between the cells. In this type of
construction, the current flows perpendicular from cell to cell
over the entire cell area thus increasing high rate capability.
However, in order for the bipolar construction to be successfully
utilized, the bipolar layer should be sufficiently conductive to
transmit current from cell to cell, chemically stable in the cell's
environment, capable of making and maintaining good electrical
contact to the electrodes, and capable of being electrically
insulated and sealable around the boundaries of the cell so as to
contain electrolyte in the cell. These features are more difficult
to achieve in rechargeable batteries due to the charging potential
that can accelerate corrosion of the bipolar layer and in alkaline
batteries due to the creep nature of the electrolyte. Achieving the
proper combination of these characteristics has proven to be very
difficult.
[0005] For maintenance-free operation, it is desirable to operate
rechargeable batteries in a sealed configuration. However, sealed
bipolar designs typically utilize flat electrodes and stacked-cell
constructions that may be structurally poor for containment of the
gases present or generated during cell operation. In a sealed cell
construction, gases are generated during charging that need to be
chemically recombined within the cell for stable operation. To
minimize weight of the structures used to provide the gas pressure
containment, the battery should operate at relatively low pressure.
The pressure containment requirement creates additional challenges
on designing a stable bipolar configuration.
[0006] Also, the need for removal of heat generated during normal
operation of batteries may be a limiting design factor in bipolar
construction due to the compact nature of the construction. Thus,
an optimum bipolar design should provide for removal of heat
generated during operation.
[0007] In U.S. Pat. No. 5,393,617, electrode structures that are
adaptable for primary and electrically rechargeable electrochemical
wafer cells are disclosed. According to an embodiment set forth in
that patent, a flat wafer cell includes conductive, carbon-filled
polymeric outer layers that serve as electrode contacts and as a
means of containment of the cell. Multi-cell, high voltage
batteries may be constructed by stacking individual cells.
Specially formulated electrodes and processing techniques that are
compatible with the wafer cell construction are particularly
disclosed for a nickel-metal hydride battery system. The cell
design and electrode formulation disclosed in the '617 patent
provide for individual operation of a vented or sealed cell and/or
for operation of these cells in a stacked array in an outer battery
housing.
[0008] The foregoing construction approach of the '617 patent is
advantageous and has proven to be flexible for designing batteries
having different capacity, voltage and chemistry. However,
scientists and engineers working under the direction of Applicant's
assignee are continually seeking to develop further improved wafer
cell and battery constructions, and methods of fabrication
thereof.
ADVANTAGES AND SUMMARY OF THE INVENTION
[0009] The present invention provides a means for achieving
desirable packaging benefits of bipolar construction for multi-cell
batteries and of overcoming material and construction problems of
some previous approaches. Although the materials of construction
for each type of cell are specific to each battery chemistry, the
general bipolar construction disclosed herein may be used for many
types of electrochemical cells. In particular, several embodiments
and examples that follow relate to the rechargeable nickel-metal
hydride chemistry but may be generally adaptable to other
chemistries.
[0010] An advantage of the present invention relates to providing a
bipolar battery construction for primary and/or rechargeable
multi-cell batteries that have improved energy storage capacity
while providing stable and efficient battery performance, as well
as long term chemical and physical stability.
[0011] Another advantage of the present invention relates to
providing a bipolar battery construction using flat electrochemical
cells having a sealed configuration.
[0012] Still another advantage of the present invention relates to
providing a bipolar battery construction wherein nickel-hydride
electrodes may be used.
[0013] These and still other advantages and benefits may be
achieved by making a bipolar electrochemical battery
comprising:
[0014] a stack of at least two electrochemical cells electrically
arranged in series with the positive face of each cell contacting
the negative face of an adjacent cell, wherein each of the cells
comprises
[0015] (a) a negative electrode;
[0016] (b) a positive electrode;
[0017] (c) a separator between the electrodes, wherein the
separator contains an electrolyte;
[0018] (d) a first electrically conductive lamination comprising a
first inner metal layer and a first polymeric outer layer, said
first polymeric outer layer having at least one perforation therein
to expose the first inner metal layer, said first electrically
conductive lamination being in electrical contact with the outer
face of the negative electrode; and
[0019] (e) a second electrically conductive lamination comprising a
second inner metal layer and a second polymeric outer layer, said
second polymeric outer layer having at least one perforation
therein to expose the second inner metal layer, said second
electrically conductive lamination being in electrical contact with
the outer face of the positive electrode; wherein the first and
second laminations are sealed peripherally to each other to form an
enclosure including the electrodes, the separator and the
electrolyte.
[0020] The present invention further relates to an electrochemical
wafer cell comprising:
[0021] (a) a negative electrode;
[0022] (b) a positive electrode;
[0023] (c) a separator between the electrodes, wherein the
separator contains an electrolyte;
[0024] (d) a first electrically conductive lamination comprising a
first inner metal layer and a first polymeric outer layer, said
first polymeric outer layer having at least one perforation therein
to expose the first inner metal layer, said first electrically
conductive lamination being in electrical contact with the outer
face of the negative electrode; and
[0025] (e) a second electrically conductive lamination comprising a
second inner metal layer and a second polymeric outer layer, said
second polymeric outer layer having at least one perforation
therein to expose the second inner metal layer, said second
electrically conductive lamination being in electrical contact with
the outer face of the positive electrode; wherein the first and
second laminations are sealed peripherally to each other to form an
enclosure including the electrodes, the separator and the
electrolyte.
[0026] The present invention still further relates to an assembly
for containing contents of a wafer cell, comprising:
[0027] (a) a first electrically conductive lamination comprising a
first inner metal layer and a first polymeric outer layer, said
first polymeric outer layer having at least one perforation therein
to expose the first inner metal layer, said first electrically
conductive lamination capable of being in electrical contact with a
negative electrode; and
[0028] (b) a second electrically conductive lamination comprising a
second inner metal layer and a second polymeric outer layer, said
second polymeric outer layer having at least one perforation
therein to expose the second inner metal layer, said second
electrically conductive lamination capable being in electrical
contact with a positive electrode, wherein the first and second
laminations are capable of being sealed peripherally to each other
to form an assembly for containing the contents of a wafer
cell.
[0029] A further advantage of the present invention relates to
enhanced conduction through the cell and/or adjacent cells due to
the ease through which current may flow through the metal layers of
the laminations exposed by the perforations.
[0030] Further advantages of this invention will be apparent to
those skilled in the art from the following detailed description of
the disclosed bipolar electrochemical batteries and methods for
producing the bipolar electrochemical batteries, and of the wafer
cells used therein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] FIG. 1 shows an overview of a wafer cell embodiment of the
invention.
[0032] FIG. 2A shows a side view of a portion of a wafer cell
embodiment of the invention and FIG. 2B shows a sectional view of a
wafer cell embodiment of the invention.
[0033] FIG. 3 shows a multi-cell stack of wafer cells, according to
the invention.
[0034] FIG. 4 shows a three-dimensional view of a multi-cell stack
of wafer cells contained in an outer battery housing, according to
the invention.
[0035] FIG. 5 shows the voltage for a cell, according to the
invention, at different discharge currents.
[0036] FIG. 6 shows the voltage for a cell, for comparison to the
invention, at different discharge currents.
[0037] FIG. 7 shows the voltage for a cell, for comparison to the
invention, at different rates.
[0038] FIG. 8 shows the voltage vs. time (life test) for a cell,
according to the invention.
[0039] FIG. 9 shows the voltage for a cell, according to the
invention, at different discharge rates.
[0040] FIG. 10 shows the charge-discharge voltage for a cell stack,
according to the invention.
DETAILED DESCRIPTION
[0041] While the following description of embodiments of the
present invention is intended to provide detailed instructions that
would enable one of ordinary skill in the art to practice the
invention, the scope of the invention is not limited to the scope
of the specific product or process details hereinafter
provided.
[0042] The bipolar electrochemical battery of the subject invention
first relates to preparing an electrochemical wafer cell 1. FIGS. 1
and 2B show schematically illustrative embodiments of a wafer cell
1 comprised of a negative electrode 2 and a positive electrode 3.
The electrodes are prevented from coming into direct physical
contact with each other by a separator 4 and are contained between
two outer layers: a first electrically conductive lamination 5 and
a second electrically conductive lamination 6 that make electrical
contact to the negative and positive electrodes, 2 and 3,
respectively. As shown in FIGS. 1 and 2B, an embodiment of the
invention comprises the electrochemical cell I wherein the
electrodes, 2 and 3, the separator 4 between the electrodes and the
two outer laminations, 5 and 6, are each substantially flat and in
tight physical contact with the adjacent component, thereby
advantageously permitting construction of a thin wafer cell.
[0043] The negative electrode 2 used in the present invention may
be any negatively charged electrode known in the art. For example,
the negative electrode 2 may be made of a material selected from
the group of cadmium, iron, hydrogen, zinc, silver, metal hydride,
lithium, lead, a lithium-carbon material, e.g. carbon containing
lithium material, and mixtures thereof. Further materials for
electrode 2 may include nickel hydrides, iron hydrides, lithium
hydride, copper hydrides and mixtures thereof. In another
embodiment of the present invention, the negative electrode 2 is a
bonded metal hydride alloy powder that can electrochemically and
reversibly store hydrogen. Such suitable electrodes include, but
are not limited to, electrode materials disclosed in U.S. Pat. Nos.
4,487,817, 4,728,586, 5,552,243, 5,698,342 and 5,393,617. In
particular, suitable alloy formulations may include, for example,
what are commonly referred to as Miscbmetal hydride alloys, which
may be comprised of an alloy of hydride-forming metals such as Mn
Ni.sub.3.5Co.sub.0.7Al.sub.0.83, AB.sub.5 type or AB.sub.2
compositions.
[0044] The positive electrode 3 may also be any suitable positively
charged electrode known in the art, including what is typically
referred to as a nickel-type electrode, or more simply, as a nickel
electrode. Nickel hydroxide is the active component of a nickel
electrode, and examples of nickel electrodes are disclosed in U.S.
Pat. No. 5,393,617, German Patent No. 491,498 and British Patent
No. 917,291. For example, the electrode 3 may be a sintered,
plastic bonded or pasted foam nickel electrode. Alternatively, the
positive electrode 3 may be made of a material other than an oxide
or hydroxide of nickel, as disclosed in the patents cited herein.
Suitable materials for the positive electrode 3 may include, but
are not limited to, oxygen, nickel, lithium, manganese, copper,
cobalt, silver, an oxide or hydroxide of manganese, an oxide or
hydroxide of copper, an oxide or hydroxide of mercury, an oxide or
hydroxide of silver, an oxide or hydroxide of magnesium, an oxide
or hydroxide of lithium (including electrodes used in lithium
rechargeable batteries) and combinations thereof. In an embodiment
of the invention, the negative electrode 2 and positive electrode 3
are flat and made in accordance with the teachings of U.S. Pat.
Nos. 5,393,617 or 5,552,242.
[0045] Electrodes 2 and 3 each may also include current collectors
for carrying current between adjacent cells. Such current
collectors may not be necessary because the current path between
adjacent electrodes is relatively short and the area of physical
and electrical contact between adjacent cells is large relative to
the total area of the adjacent components. In addition, the
electrodes are typically conductive enough for cell operation
without having current collectors that add weight and complexity to
the cell.
[0046] The electrodes 2 and 3 may be prevented from coming into
direct physical contact with one another by use of separator 4
which extends beyond the edge of the electrodes 2 and 3, as shown
in the embodiments of FIGS. 1 and 2B. The separator 4 is typically
made of synthetic resin fibers such as polyamide or polypropylene
fibers. The separator 4 may also be made of a material including,
but not limited to, inorganic layers or other suitable separator
material known those skilled in the art. The separator 4 is flat
and has a porous structure for absorbing and containing an
electrolyte within the cell 1, in an embodiment of the
invention.
[0047] Typically, for alkaline chemistries the electrolyte includes
an aqueous solution of one or more alkali hydroxides such as
lithium hydroxide, sodium hydroxide and potassium hydroxide. In an
embodiment of the invention, the separator 4 comprises two layers
of non-woven polyolifin and the electrolyte comprises an alkaline
solution. In a further embodiment of a nickel-metal hydride system,
the alkaline solution is a mixed hydroxide of potassium and lithium
hydroxide.
[0048] The electrodes, 2 and 3, and separator 4 may be contained
within the wafer cell 1 by use of a first electrically conductive
lamination 5 and second electrically conductive lamination 6, which
Applicant has determined provides advantages over prior approaches.
The first lamination 5 is equal and opposite to the second
lamination 6, as shown in the embodiments of FIGS. 1 and 2B. The
first lamination 5 comprises a first inner metal layer 7 and an
first polymeric outer layer 8. The first polymeric outer layer 8
has at least one perforation 9 or opening therein, as shown in the
embodiment of FIG. 2A, to expose the first inner metal layer 7 and
provide a contact point for conduction through the cell 1.
Similarly, the second lamination 6 comprises a second inner metal
layer 7a and a second polymeric outer layer 8a. The second
polymeric outer layer 8a also has at least one perforation 9a
therein to expose the second inner metal layer 7a and also provide
a contact point for conduction through the cell 1. Perforations 9
and 9a may be aligned with respect to each other to provide optimum
conduction from cell to cell, as shown in the embodiment of FIG.
3.
[0049] Metal layers 7 and 7a of the laminations may be made of any
metallic material and in various shapes and sizes. For example,
metal layers 7 and 7a are each made of a thin metal foil of the
same size as that of the negative electrode 2 and positive
electrode 3, respectively, and aligned with the respective
electrode as shown in the embodiments of FIGS. 1, 2B and 3. Several
layers may also be employed. Suitable materials for the metal
layers 7 and 7a include, but are not limited to copper, aluminum,
steel, silver, nickel and mixtures thereof, including plated
materials readily known to those skilled in the art. The foil
thickness may be as thin as practical, for example, between about
0.0003 inches and about 0.005 inches, depending upon design
specifications and to meet the needs thereof.
[0050] In order to enhance electrical contact, a conductive paste
or cement such as a conductive epoxy or other suitable material
readily known to those skilled in the art may be applied between
each of the metal layers and the respective electrode with which it
is in contact. Thin layers of conductive cement 0.0005 to 0.001
inches thick may serve this purpose.
[0051] The first and second polymeric outer layers 8 and 8a of the
laminations may be made of any suitable polymeric material
including, but not limited to, nylon polypropylene, polyethylene,
polysofon, polyvinyl chloride and mixtures thereof. The materials
of polymeric outer layers 8 and 8a need not be electrically
conductive. An advantage of this feature is that the choice of
material for the polymeric outer layers is therefore not limited to
such a requirement. In an embodiment, each layer 8 and 8a is a
layer of polypropylene film, between about 0.001 and about 0.003
inches in thickness. Each layer 8 and 8a may also be heat sealable
and chemically stable in the cell environment.
[0052] The first polymeric outer layer 8 may be affixed to the
first inner metal layer 7 to form the lamination 5 by any suitable
sealing mechanism which thereby creates a sealed interface 11.
Similarly, the second polymeric outer layer 8a may be affixed to
the second inner metal layer 7a to form the lamination 6 by any
suitable sealing mechanism, which thereby also creates a sealed
interface 11a. For example, suitable sealing mechanisms include,
but are not limited to, use of bonding agents of asphalt, tar,
neoprene, rubber, epoxy, cement and combinations thereof
[0053] In one embodiment of the invention, a potential leakage path
for the electrolyte from the cell 1 is along the interface (11,
11a) between the first or second inner metal layers (7, 7a) and the
respective first or second polymeric outer layers (8, 8a) around
the edge of the metal layer to the closest location of a
perforation. To produce an effective seal, an appropriate contact
material such as cement, which is chemically stable in the cell's
electrolyte environment, may be applied around the edges of the
perforation(s) in amounts such as about 0.0003 to 0.001 inches
sufficient to cover the interface and thereby prevent any potential
leakage. Suitable contact cements include, but are not limited to
asphalt, tar, neoprene, rubber, epoxy, cement and combinations
thereof.
[0054] In order for the electrodes, 2 and 3, the separator 4
between the electrodes and the electrolyte to be contained within
an enclosed wafer cell, the first and second polymeric outer layers
8 and 8a of the laminations 5 and 6 may have a larger physical area
than the electrodes around the entire perimeter of the adjacent
electrode, as shown in FIGS. 1 and 2B. Additionally, the first and
second polymeric outer layers 8 and 8a which also extend beyond the
inner metal layers 7 and 7a, respectively, are advantageously
affixed to each other to provide a seal around the perimeter of the
wafer cell 1, in an embodiment of the invention. Such sealing along
the perimeter, which may create a plastic to plastic joint 10, can
be accomplished by any suitable known technique including, but not
limited to, heat sealing or utilizing a cement or a filler material
that bonds to the material of the polymeric outer layers 8 and 8a.
Accordingly, this advantageously results in a sealed enclosure for
the wafer cell 1.
[0055] The enclosed wafer cell 1 may be completely sealed or it may
be provided with one or more vents or relief valves to relieve
excess pressure built up during charging. Since the flat cell
construction may not be an optimum physical configuration for a
pressure-containment vessel, the use of hydride alloys that operate
at atmospheric pressure may be particularly useful. If a completely
sealed configuration is used, a design that is electrochemically
limited by the capacity of the positive electrode may also be
advantageous. For this type of design, oxygen gas is generated at
the end of the charging cycle at the positive electrode before the
total available hydrogen storage capacity of the hydride electrode
is fully utilized. Oxygen produced at the positive electrode may
migrate to the negative hydride electrode and chemically recombine
with the hydrogen in the hydride electrode so as to help prevent
excessive buildup of pressure. The chemical recombination of oxygen
and hydrogen is referred to herein as the oxygen recombination
reaction. Accordingly, the teachings of U.S. Pat. No. 5,393,617,
disclosing, for example, means for enhancing the migration of
oxygen gas to the negative electrode and for promoting efficient
chemical recombination of the oxygen with hydrogen at the hydride
electrode surface, may be of interest.
[0056] One skilled in the art would also appreciate that the wafer
cell 1 may be fabricated in a dry state and provided with a fill
port through one of the laminations 5, 6 for vacuum filling or
pressure filling which then may be sealed with an appropriate
patch. In this technique, the air in the cell may be vacuumed from
the filing port provided in the cell and the differential pressure
will force electrolyte into the pores of the electrodes and
separators. Alternatively, the electrodes 2, 3 and separator 4 may
be pre-moistened or pre-wet with an appropriate amount of
electrolyte before the afore-referenced perimeter seal is made on
the wafer cell 1. For example, the electrolyte quantity introduced
into the cell may fill 60 to 90% of the pore volume of the
electrodes and separators.
[0057] In an embodiment of the invention, the first electrically
conductive lamination 5 is in electrical contact with the outer
face of the negative electrode 2 via at least one perforation 9, as
shown in FIGS. 1 and 2B. Similarly, the second electrically
conductive lamination 6 is in electrical contact with the outer
face of the positive electrode 3 via at least one perforation 9a,
as also shown in FIGS. 1 and 2B. Thus, Applicant's lamination
design including perforations 9 and 9a advantageously enables
electrical contact to be made to the positive and negative faces of
the cell 1, as well as through the cell 2 and/or adjacent cells.
The size and spacing of perforations 9 and 9a may be determined by
a number of design factors for optimum sealing and electrical
current carrying capacity. For example, an arrangement is to keep
the perforations 9 and 9a at least a 1/4 inch from the foil edges.
The size and the perforation spacing may be determined by the
electric requirements of the cell.
[0058] Referring now to FIG. 3, an embodiment of a multi-cell
battery stack 14 of the invention is shown therein which may be
made by stacking several wafer cells 1. The wafer cells are
electrically arranged in series with the positive face of each cell
contacting the negative face of the adjacent cell. In this
embodiment, the electric conduction path through the stack 14 is
advantageously from the electrode to a metal foil layer, internally
through the foil to a perforation, and through the perforation to
the adjacent cell in the stack 14.
[0059] The end cells of the battery stack also may have metal foil
contacts, as described in U.S. Pat. 5,393,617, to conduct the
electric current from the battery stack to the battery terminals.
The cell-to-cell contact or the contact between the end cells and
the foil at the perforation points may also be enhanced by the use
of a material such as conductive paste, cement or metallic filler
disk. The compact stack assembly may be held in compression to
ensure uniform physical contact between the adjacent cells and
between the respective layers within each cell. The stack
compression may be achieved by means of rigid end plates having
external tie rods wrapped around the perimeter of the stack, or by
having internal tie rods that penetrate through sealed holes
provided in the individual electrochemical cells, as described for
instance in U.S. Pat. No. 5,393,617. The holes may be sealed to
prevent leakage and electrical contact between the tie rods and the
electrically conductive components of the cell.
[0060] Alternatively, the stack may be contained in an outer
battery housing 12, as shown in FIG. 4. To allow for electrode
expansion and irregularities in the stack, the stack may be held in
compression by means of a layer of sponge rubber, between one or
both of the metal foil contacts and the end plates of the outer
housing. A spring or a gas-filled compressible pad 13 or bladder
may be also used instead of sponge rubber. Similarly, the battery
may be contained in a housing with a honeycomb plate for
lightweight ridge containment of a cell stack. For example, to
reduce the weight of the end plates, ribbed designs or honeycomb
sheets familiar to those skilled in the design of lightweight
structures may be used. Also, if the cell stack is-contained in an
enclosed outer housing, the outer housing may serve to provide
stack compression and the housing may be sealed or vented.
[0061] The multiple cells may each may have small vent ports and
the cells may be contained in a sealed container which serves as
the battery housing. If the cells are vented, the battery housing
may be provided with a conventional pressure measuring device. Such
a device may be a pressure gauge, a transducer and/or a pressure
switch. The pressure measuring device may be used for monitoring
the battery pressure and for regulating the magnitude and duration
of the charging current during the charge cycle. Such regulation of
the charging current is herein referred to as charge control. The
stack may also contain internal tie rods to insure uniform
compression and contact over the entire plane of the cells. The
sealed container may further have a pressure relief valve to vent
internal gases. The individual wafer cells 1 may be made according
to the descriptions herein and other battery components, such as
pressure gauges, etc., discussed above may be made using known
methods or obtained from supply sources known to one skilled in the
art.
[0062] For improved heat transfer, an additional metal foil layer
or layers may be placed between or periodically between the cells,
as desired. Alternatively, the cell edges may be extended to
improve the thermal interface to the side walls of the battery
housing. For example, for stable thermal operation, heat generated
during battery operation should be removed from the perimeter of
the battery. To improve internal heat transfer, an additional metal
foil layer may be placed in the stack, as desired, for example such
as adjacent to a metal layer and/or polymeric layer. Additionally,
the cell edges may be extended to contact the side walls of the
battery housing to insure thermal contact to the side walls.
[0063] The examples which follow describe the invention in detail
with respect to showing how certain specific representative
embodiments thereof can be made, the materials, apparatus and
process steps being understood as examples that are intended to be
illustrative only. In particular, the invention is not intended to
be limited to the methods, materials, conditions, process
parameters, apparatus and the like specifically recited herein.
[0064] Throughout this application, various patents have been
referred to. The teachings and disclosures of each of these patents
in their entireties are hereby incorporated by reference into this
application to, for example, more fully describe the state of the
art to which the present invention pertains.
[0065] It is to be understood and expected that variations in the
principles of invention herein disclosed may be made by one skilled
in the art and it is intended that such modifications are to be
included within the scope of the present invention.
EXAMPLES OF THE INVENTION
Example 1
[0066] A single wafer cell including one positive nickel electrode
and one negative metal hydride electrode was fabricated in an
arrangement as shown in FIG. 1. The electrodes were prepared
according to the procedures described in U.S. Pat. No. 5,393,617.
In particular, the hydride electrode was prepared by blending a
mixture of 45 grams of a Mischmetal hydride alloy, 0.5 grams of
PTFE (Teflon.RTM.) powder and 4.5 grams of CuO. The Mischmetal
hydride alloy used herein was comprised of an alloy of Mn
Ni.sub.3.5Co.sub.0.7Al.sub.0.8. The hydride alloy, received as
about 1/8 to 1/4 inch particles, was fragmented by dry pressure
hydrating five times between vacuum and 200 psi to produce an
average particle size of about 50 microns. The mixture was blended
in a high speed blender for two30-second periods. The mixture was
then rolled out to a layer approximately 0.060 inch thick, and then
folded and rolled to a 0.060 inch thickness in a direction about 90
degrees from the original direction. The above folding and rolling
in the rotated direction was sequentially repeated seven times to a
point wherein the (PTFE) Teflon.RTM. powder was fibrillated to form
a fibrous, lace-like network which contained and bonded the other
ingredients. For each step, the folding and rolling was carried out
in a direction about 90 degrees from the folding and rolling
direction of the immediately preceding step. The strip was then
calendered to a final thickness of 0.020 inches. A 3.times.3 inch
electrode, weighing 11 grams, was cut from the strip for assembly
in the cell.
[0067] The nickel electrode was prepared using a method similar to
that described for the hydride electrode. The mixture contained 1
gram of (PTFE) Teflon.RTM. powder, 1.5 grams of cobalt monoxide, 15
grams of graphite powder and 32.5 grams of nickel hydroxide powder.
The final strip was calendered to a thickness of about 0.040
inches. A 3.times.3 inch electrode weighing 10 grams was cut from
the strip. The electrode was then pressed at about 2,000 psi in a
hydraulic press to a thickness of about 0.033 inches prior to
assembly in the cell. Two layers of a non-woven nylon separator
31/8.times.31/8 inch square were placed between the electrodes.
[0068] The outer envelop of the cell was constructed from two
electrically conductive laminations each prepared by bonding a 2
mil thick nickel foil, 3.times.3 inch square, to a 3 mil thick
layer of polypropylene film that was 31/4.times.33/4 inch square.
The bonding agent utilized was a solvent mixture of tar asphalt
having a concentration of 30% solids. This bonding agent was
painted on the foil, allowed to dry until tacky and then laminated
to polypropylene by pressing lightly. The cement bonding layer was
approximately 0.001 inches thick.
[0069] Prior to bonding, four 1/4 inch diameter holes were punched
through the polypropylene film with the use of a die at a spacing
of 11/2 inch on centers in a square pattern such that each contact
point of nickel foil essentially served a quarter section of the
electrode 3/4.times.3/4 inch square, as shown in FIG. 2A.
[0070] The cell was constructed by stacking the afore-described
nickel electrode, separator layer and metal hydride electrode in
the two outer lamination layers, as shown in FIG. 2B. The assembly
was then heat sealed around the perimeter border to provide a 1/8
inch heat seal around the outer edges of the cell. The
polypropylene film and metal foil of the lamination adjacent the
negative electrode included a 1/8 inch hole in its center for
electrolyte filling.
[0071] For testing purposes, a nickel foil contact plate with a
thickness of 0.005 inches was placed on the outer positive and
negative faces of the outer layers of the cell assembly. The cell
assembly was then placed between two rigid acrylic plates which
contained a filling port and peripheral bolts to hold the assembly
together and maintain the cell in a compression for testing of
individual cells.
[0072] The cell was then vacuumed filled by a technique in which a
vacuum is drawn from the filling port to remove all air from the
cell and then an electrolyte is allowed to flow back into the cell.
Specifically, the cell was filled with 30% KOH-1% LiOH electrolyte,
allowed to soak for 24 hours and then subjected to three formation
cycles. Each formation cycle included 81/2 hour charge at 200 mA
and discharge at 500 mA to 0.8 volts, or a maximum elapsed time of
31/2 hours. The cell was then tested at different discharge rates
as shown in FIG. 5. The cell was recharged at the standard 81/2
hour rate between recharges.
[0073] FIG. 5 shows the cell voltage of this cell at different
discharge rates. The results obtained advantageously demonstrate
the high rate capacity of the present invention.
Example 2
[0074] For comparison with the present invention and to demonstrate
the advantageous results of the invention, a single cell was
constructed as described in Example 1 except that the two sheets of
2 mil nickel foil, 3.times.3 inch square, of Example I were
increased to 31/4.times.31/4 inch square, and the two 3 mil layers
of polypropylene film that were 31/4.times.31/4 inch square were
not utilized. The nickel foil sheets were then epoxy bonded
directly around the perimeter of the cell. This edge seal served
for temporary testing, but may allow electrolyte leakage under
endurance testing.
[0075] This cell configuration is not the subject of the present
invention because it did not employ Applicant's advantageous
laminations 5 and 6, as described herein. However, testing of this
cell configuration under the conditions described in Example 1 was
useful to demonstrate the advantages of Applicant's present design.
In particular, testing demonstrated that the current power capacity
of a cell without the outer polymeric film was similar to that of
Applicant's invention described in Example 1 which included a
polymeric film having the perforations therein to expose the metal
foil and establish conduction through the cell. FIG. 6 shows the
cell voltage of this cell different rates. A comparison of FIGS. 5
(re: Example 1) and 6 shows that the voltage characteristics are
similar.
Example 3
[0076] In further contrast to the present invention, a cell was
assembled and tested as in Example 1 except that the outer layers
of the cell were made of a carbon-filled conductive polymeric
material of polyvinyl chloride (pvc) nominally 4 mils thick and the
outer edges of the cell were heat sealed to a non-conductive
polymeric material of pvc to form the edge seal, as described in
U.S. Pat. No. 5,393,617. Accordingly, Applicant's laminations of
metallic foil/perforated polymeric layer were not employed.
[0077] This example demonstrated the less effective high rate
current capabilities of the carbon-filled conductive outer film, as
compared to that of Applicant's invention including its
advantageous laminations. In particular, FIG. 7 shows the voltage
current characteristics of this cell. A comparison of FIGS. 5 (re:
Example 1) and 7 demonstrates that the present invention has a
higher rate capability.
Example 4
[0078] In accordance with the present invention, a cell was
constructed as in Example 1 except that in place of heat sealing
the outer polymeric layers to form the perimeter outer seal, an
epoxy cement was filled in along the border of the perimeter of the
cell by injecting into the gap around the edges of the cell and
allowed to cure for about 2 hours. After three formation cycles of
8.5 hours charge, 3.5 hours discharge, the excess electrolyte was
drained from the cell by charging the cell in the upside down
position to allow any free liquid to be ejected from the cell.
After this step, a pressure gauge was then mounted into the fill
port of the outer plastic acrylic plate to seal the internal
compartment of the cell from the outside environment. The cell was
then subjected to a life test at 40% depth of discharge on a cycle
of 55 minutes of charge, 35 minutes of discharge at 0.72 and 1.1
amperes current, respectively.
[0079] FIG. 8 shows the voltage performance characteristics of this
cell over testing for 5,000 cycles. As can be seen from this
figure, stable performance was achieved, thus demonstrating the
stability of the seal materials and design.
Example 5
[0080] According to the present invention, a cell was constructed
in a configuration similar to Example 1 except the positive and
negative electrodes were each 6.times.6 inches square. The
laminations also each included a 61/4.times.61/4 inch polypropylene
film bonded to a 1 mil metal foil, 6 inches square, using tar. Each
polypropylene film included a 1/4 inch diameter perforation pattern
of 1 inch centers from hole to hole so that each contact point
essentially serviced an electrode area 1.times.1 inch square.
[0081] FIG. 9 shows the voltage current characteristics of this
cell at different discharge rates and demonstrates the high rate
capability of the invention and the effectiveness of the seal
design.
Example 6
[0082] In further accordance to the present invention, a stack of
five sealed cells was assembled in an arrangement as shown in FIG.
3 to make a nominal 6 volt battery. The individual cell
construction was the same as that of Example 4 except the fill port
of each cell was sealed with a cemented patch. FIG. 10 shows the
charge-discharge voltage of the stack.
[0083] FIG. 10 advantageously demonstrates that a multi cell stack
may easily and effectively be constructed using Applicant's
design.
[0084] In view of the foregoing examples and descriptions of the
present invention, it can be seen that the present invention
advantageously provides stable cycling sealed cell operation.
[0085] Another advantage of the present invention is high power
capability.
[0086] A further advantage of the present invention is a convenient
construction approach.
[0087] A still further advantage of the present invention is a cell
and battery design that minimizes wasted space and has a high
active to inert weight ratio.
* * * * *