Abstract: Blisters or air bubbles between battery layers can be a problem with the lamination of battery layers. The blistering can be reduced by a two-step pressure-applying method. In the first step, a relatively small first pressure is applied to the battery layers. The relatively small first pressure is done such that air bubbles between the battery layers are not formed. Next, a second larger pressure is applied to the battery layers to laminate the battery layers together. In an alternate embodiment, the pressure applied to the battery layers is changed from a low pressure to laminating pressures in one step.

Abstract: Heat and pressure can be used to re-flow active material at the edges of an electrode section to coat burrs at the edges of the electrode section. These burrs are typically formed in the cutting of the current collector and active material to form the electrode sections. By coating the burrs with the active material, shorts are prevented when the electrode sections are laminated with the other battery sections to form a battery stack.

Abstract: A new technique for securing into place a plurality of layers which make a battery body, and for preventing electrical short-circuits within the battery by retarding the formation of dendritic growths is disclosed. A radiation curable layer of material is coated onto a portion of at least one outwardly exposed face of a battery body, whereupon the layer of material is then cured. The cured layer of material is positioned relative to the body such that the cured layer provides support to the body in a manner to secure in place a plurality of layers which make up the battery body, thereby ensuring proper electrical contact between the plurality of layers. In addition, the cured layer of material is also positioned such that the cured layer inhibits formation of short circuiting electrical paths between the anode and cathode layers of the battery, the paths being caused by formation of dendritic growths extending out from the anode layer towards the cathode layer.

Abstract: The present invention concerns forming a masked area on a porous separator material for use in a battery. Masked areas can be formed on the porous separator material with heat and/or pressure. The use of a masked area allows for easier alignment of the anode and cathode sections, such that edge effects do not occur. Edge effects, which result from the electrode sections having different surface areas, can cause differential current densities at the corners and edges of the electrode sections. This inhomogeneous cycling of the anode and cathode can cause premature cycle fade of the battery. The edge effects can also include dendritic growth of a lithium anode. The mask separator section can be connected to a solid electrolyte and a cathode section to form an assembly. This assembly can be later combined with an anode assembly to form a battery cell.

Abstract: In order to maintain electrical contact between the anode, cathode and electrolyte layers in an electrochemical cell, a layer of material under tension is wrapped around the cell so that the material compresses the layers together to ensure sufficient electrical contact. Alternatively, a metal, foam or inflatable gas spring is employed in a housing structure containing the electrochemical cell to apply a compressive force to achieve the same result.

Abstract: In making a laminar assembly for use in the battery, a layer of battery electrode material is deposited onto a substrate surface and the battery electrode material is caused to have an uneven surface. Then an electrolyte layer is deposited onto the uneven surface of the battery electrode material. Where the method calls for first depositing the electrolyte material, then electrolyte material is deposited onto the substrate layer where the electrolyte layer is caused to have an uneven surface. Thereafter, the battery electrode material is deposited onto the uneven surface of the electrolyte material. In both cases, slippage between the battery electrode material and electrolyte material is reduced during cutting, folding and other handling process in making a laminar battery, thereby reducing the probability of shorts in the battery.

Abstract: An apparatus for shielding adjacent batteries during testing includes a shell with partitions to form an array of pockets, and a cover with shields. When a cover is placed in a closed position on top of the shell, each shield would contact a corresponding partition to completely isolate two batteries placed in two pockets adjacent to the shield and partition. In this manner, even if a battery catches fire or leaks, the partition and the shield minimizes the effect on an adjacent battery.

Abstract: In a magnesium battery, a magnesium foil envelope encloses a current collector, cathode layers on the current collector, and an electrolyte material separating the cathode layers from the foil envelope to form the battery. The magnesium foil envelope serves as the packaging so that no extra packaging is required. The current collector has an elongated portion which protrudes through the magnesium foil to serve as a battery terminal and the magnesium foil is sealed around the battery terminal and is electrically insulated from it by an insulating layer or adhesion layer.