Rayovac Corporation

Johnson Research Development Company, Inc.

Other

John Manufacturing Limited

Daniel A Schneider

Timothy J Stachoviak

Shirley A Craanen

Joseph P Nestler

James H Annen

Lonnie G Johnson

El-Sayed A Megahed

Jack T West

Jackson C Ma

Marek K Kokoszka

Amy K Lawrence

A secondary battery separator comprises a fibrous core coated with a polymer having improved electrode adhesion properties in unitary laminated construction. Vacuum removal of plasticizer without solvent extraction prevents brittleness and results in microporosity in a thin layer of enhanced ion conductivity.

Lithium battery with secondary battery separator

An electrode and separator composite comprises a separator and an electrode embedded in a polymer matrix. Application of an electrode slurry to a polymer coated separator and subsequent drying in a solvent enriched atmosphere forms a secondary battery structure characterized by a seamless composite structure.

Composite separator and electrode

Arc spray deposition of molten metal droplets on plastic electrodes creates a tight bonded adhesion and increases the surface area contact between collector and electrode. This is especially efficacious for lithium secondary batteries which are known to flex during charge and discharge cycles leading to battery failure. The strength of the bonding interaction, and a resistance to stress cracking are observed when a perforated or expanded metal strip is utilized to reinforce the arc spray deposited metal collector.

Current collector manufacture by arc spray deposition

A secondary battery separator comprises a fibrous core embedded in a polymeric sheet having improved electrode fusion thereto in unitary construction. In the process of manufacturing the separator, a fibrous, polymeric, substantially two-sided core matrix is coated with a polymer mixture containing a plasticizer and a solvent vehicle, and a vacuum is applied to the reverse side from the coated side to cause the polymer mixture to penetrate and infuse the capillary voids of the core matrix from the opposite coated side. The vacuum is continued until the solvent vehicle is fully volatilized. After the solvent vehicle has dissipated, the fiber matrix is turned over, and the process is repeated by applying a coating of polymer mixture to the second side and pulling a vacuum on the opposite side to cause penetration of the matrix.

Unitary separator and electrode structure and method of manufacturing

This invention pertains to electrochemical cells, and specifically to an inner seal member in an electrochemcical cell. The inner seal member is positioned against, and in intimate contact with that portion of the separator which extends above the cathode mix, or a retaining washer on the cathode mix, and is also in intimate contact with the cathode mix or the retaining washer. The seal member is preferably emplaced as a fluid material and is preferably distributed by centrifugal force, by rotating the cell as the sealant material is dispensed into the cell. The inner seal member is effective to retard loss of battery performance over an extended period of storage time, both at room temperature and at elevated temperature. The seal member is a composition of hydrocarbons or fatty acid ester oils having the capacity to remain in full surface-to-surface contact, as it cools, with the surfaces upon which it is placed warm or hot, in the cell.

Electrochemical cell having an inner seal member

An improved dry cell seal closure is disclosed which will substantially prevent moisture loss from and/or oxygen ingress into a battery cell while maximizing the volume available within the cell for the cathode mix core. The seal closure comprises a seal member, such as a plastic washer, placed on top of the cell, covering all of the edge of the domed lip; sealing means, such as an adhesive coated plastic tape, adhesive coated shrink film wrap or shrink film tube, positioned to cover all of the edge and at least part of the upper surface of the seal member and to extend over at least a portion of the side of the cell, thus holding the seal member in place; a compression member placed over the seal member to partially cover the sealing means, further securing the seal member and creating a seal between the seal member and the domed lip of the cell and between the seal member and the metal terminal member of the battery an insulator tube placed around the cell and extending over at least a portion of the top of the metal terminal member; and an outer jacket covering the insulator tube and dry cell which extends radially inwardly over a portion of the top of the metal terminal member so as to exert and maintain adequate sealing pressure on said metal terminal member, said compression member, said sealing means, and said seal member.

Growing community of inventors

Madison, WI, United States of America

Daniel A Schneider