Abstract: A manufacturing process and an apparatus to carry out the process are disclosed which eliminate or at least significantly reduce the occurrence of damaging localized short circuits in the production of electrochemical generators. The process and apparatus include cauterization by oxidation of the anode edges of multiple electrochemical cell laminates thereby rendering the anode edges electrically insulated from adjacent cathodes and/or current collectors.

Abstract: An apparatus and method provide for automated converting of a web of a thin patterned catalyst-coated membrane to separate membrane sheets for fuel cell assembly. The membrane typically has a thickness of about one thousandth of an inch. Automated web converting involves transporting, with use of a movable vacuum, an end portion of the membrane web from a first location to a second location. With use of respective first and second vacuums at the first and second locations, and after removal of the movable vacuum, the end portion of the membrane web is releasably secured at the first and second locations. The membrane web is cut within a gap defined between a single catalyst pattern of the membrane web end portion and an adjacent catalyst pattern to produce a membrane sheet. The membrane sheet is precisely positioned to a desired orientation to facilitate subsequent processing of the membrane sheet.

Abstract: An packing apparatus for an automated manufacturing system of a secondary lithium battery is disclosed.

Abstract: The present method corrects a warp in a separator (78) applied with a sealant (97) during production of fuel cells. The correction is performed at a correcting device (47). With the warp being corrected at the correcting device, a membrane/electrode assembly is superimposed on the separator.

Abstract: A secondary battery apparatus according to this invention includes mechanisms for delivering a positive electrode sheet and a negative electrode sheet, a first coating mechanism and a second coating mechanism for applying electrolyte-containing solutions to both surfaces of the positive electrode sheet and negative electrode sheet, respectively, a first heating mechanism and a second heating mechanism for fixing an electrolyte applied to the positive electrode sheet and negative electrode sheet, and a winding mechanism for winding, into a predetermined form, the positive electrode sheet and negative electrode sheet with the electrolyte fixed thereto.

Abstract: According to known methods, gas chambers of fuel cells are sealed by applying pressure. A small space always remains between the electrode and the membrane. According to the inventive sealing method, the bipolar plate and the membrane-electrode unit are bonded with a curable polymer. A gas-proof assembly is obtained by applying an adhesive bead on the outer periphery of the gas chamber and around the inner gas ducts. These assemblies can be stacked and bonded together according to the present invention to form a stack of polymer electrolyte fuel cells. The inventive assemblies which are composed of a bipolar plate and a membrane-electrode unit can be used in polymer electrolyte fuel cells and in corresponding electrolytic cells. These assemblies have such a small weight that they can be used in mobile devices in a particularly advantageous manner.

Abstract: An installation for manufacturing accumulators employs a plurality of pallets for supporting the accumulators, a loading station (3), an unloading station (4), a power supply (5), and an electrolyte feeder (6). A casing (7) with projecting supports (8) is positioned side by side and aligned in vertical direction for supporting the pallets to create the same number of accumulator (A) manufacturing stations, and a handler (10) moves the pallets (2).

Abstract: A lamination apparatus for an automated manufacturing system of a secondary lithium battery is disclosed.

Abstract: An automated manufacturing system of a secondary lithium battery is disclosed.

Abstract: The invention provides an apparatus and method for producing multilayer laminates of polymeric electrolyte material incorporating one of more electrode layers. The apparatus (40) comprises an extrusion apparatus (42) for extruding a polymeric material (76) and a pair of heated rollers (46, 48) between which the material (76) and electrodes (60, 68, 72) are pressed in order to produce a continuous extrudate (80). The method may also include producing a gellable mixture comprising a crystallisable polymer and an aprotic organic liquid, forming the mixture as an elongate tape and contacting the tape with an electrode material. A compression and heating step may be present.

Abstract: Stacking porous and non-porous material layers involves applying vacuum to a first porous layer to stabilize same relative to a support structure. The support structure and/or a non-porous layer are moved to establish contact between the non-porous layer and the first porous layer. The first porous and non-porous layers define a sub-assembly. While applying vacuum to the sub-assembly, one or both of the support structure and a second layer are moved to establish contact between the second layer and the non-porous layer. Vacuum applied to the sub-assembly maintains positional stability of the sub-assembly layers relative to the support structure while the second layer is moved into contact with the non-porous layer. Vacuum is subsequently removed to facilitate transporting of the material layer stack. Material layers of a fuel cell, including first and second fluid transport layers and a membrane, are well suited for automated stacking.

Abstract: A production device for a secondary battery, comprising a mechanism for feeding an anode sheet-like material and a cathode sheet-like material, a first painting mechanism and a second painting mechanism respectively painting the both surfaces of the anode sheet-like material and the cathode sheet-like material with an electrolyte-containing solution, a first heating mechanism and a second heating mechanism for fixing the electrolyte applied to the sheet-like materials, a separator feed mechanism for supplying a separator used to overlap electrolyte-fixed sheet-like materials one upon another in an insulated condition, and a winding mechanism for winding the electrolyte-fixed anode sheet-like material, and insulation sheet, a electrolyte-fixed cathode sheet-like material and an insulation sheet in a laminated condition into a specified shape.

Abstract: The invention describes a method and a device for introducing volatile liquids into housings of electrical components, in particular of passive electrical components or of electrochemical cells, and for closing the housings. The method can be carried out using an evacuable chamber (1), a conveyor device (2) for conveying the components (4), a gas pressure device (9, 12, 13, 14) for generating a gas pressure atmosphere in the chamber, a filling device (5, 8, 11, 15) for introducing a volatile liquid into a component (4), a closing device (6, 17) for closing the component (4), and using a programmable sequence control means (10), which controls the conveyor device (2), the gas pressure device (9, 12, 13, 14), the filling device (5, 8, 11, 15) and/or the closing device (6) in such a way that these devices interact in a predetermined manner.

Abstract: An apparatus and method provide for automated converting of a web of a thin patterned catalyst-coated membrane to separate membrane sheets for fuel cell assembly. The membrane typically has a thickness of about one thousandth of an inch. Automated web converting involves transporting, with use of a movable vacuum, an end portion of the membrane web from a first location to a second location. With use of respective first and second vacuums at the first and second locations, and after removal of the movable vacuum, the end portion of the membrane web is releasably secured at the first and second locations. The membrane web is cut within a gap defined between a single catalyst pattern of the membrane web end portion and an adjacent catalyst pattern to produce a membrane sheet. The membrane sheet is precisely positioned to a desired orientation to facilitate subsequent processing of the membrane sheet.

Abstract: A method and apparatus of unloading a battery group from a jig box including engaging the bottom of group on a support, releasing the grip of the jig box on the group, raising the support and gripping the raised group.

Abstract: Positive and negative electrode plates, after being dried, are layered alternately upon one another with intervening separators therebetween to constitute electrode plate groups. These electrode plate groups are transferred in succession from one to another of a plurality of preliminary chambers, which are respectively constructed to be able to create vacuum of various levels and arranged so that the vacuum level is gradually increased, and finally introduced into a processing chamber in which the vacuum level is highest, where the welding of collector plates to the electrode plate groups is performed with an electronic beam irradiating device. After that, the electrode plate groups are taken out through a post-processing chamber.

Abstract: The present invention provides high-throughput systems and methods for the fabrication and evaluation of electrode and electrolyte materials for solid oxide fuel cells. The present invention includes systems and methods for synthesizing and optimizing the performance of electrodes and electrode-electrolyte combinations and utilizes small-scale techniques to perform such optimization based on chemical composition and variable processing. Advantageously, rapid device performance systems and methods coupled with structural and surface systems and methods allow for an increased discovery rate of new materials for solid oxide fuel cells.

Abstract: An membrane electrode assembly for a fuel cell composed of a pair of electrode catalyst layers and an electrolyte membrane sandwiched between the electrode catalyst layers is configured so that the catalyst of at least one surface of the electrode catalyst layers enters in the electrolyte membrane whereby the electrode catalyst layer and the electrolyte membrane are unified with each other. In this configuration, no exfoliation occurs at the interface between the electrode catalyst layer and the electrolyte membrane, and the durability of the membrane electrode assembly can be increased even during the course of heat cycles.

Abstract: A separator is inserted into a slit formed in a winding core. A negative electrode plate made of thin metallic foil is fed toward the winding core as being held around the circumferential surface of a tape suction drum that is rotatably supported. The tape suction drum and the winding core are brought in mutual contact under pressure with their respective axes in parallel, and the winding core is driven to rotate, so that the tape suction drum is synchronously rotated with the winding core, by means of the frictional force acting between them, whereby the negative electrode plate held on the tape suction drum is wound onto the winding core together with the separator.

Abstract: A method for placing an edge piece on a battery plate includes bending a thin strip of bendable plastic material into an open top, U-shaped channel. The channel is then cut into an edge piece having a length which is substantially equal to the edge of the battery plate which is to be covered. The edge piece is supported with this open top oriented towards a battery plate that is transported toward it in a manner such that the battery plate edge will be inserted into it. Once the edge of the battery plate has been inserted into the edge piece the edge piece is released so that the battery plate can be carried out of the apparatus. An apparatus for accomplishing this includes a feed mechanism which transports the strip of bendable plastic material. A bending mechanism forms this strip into the open top, U-shaped channel. The channel is then fully inserted into an assembly station where a first sensor stops the feed mechanism and a cutter cuts the channel into the proper-sized edge piece.

Abstract: The present invention discloses a method for preparing a lithium battery with self-adhesive polymer electrolyte. The characteristic of the method is to pour a polyacrylonitrile-based solution into a battery with electrode plates and separators. An organic solvent is then poured into the battery, during which time the polyacrylonitrile-based solution is phase-separated, resulting in the adhesion of the electrode plates and separators.

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.

Abstract: A battery is made by drop on demand printing a first electrode pattern and a second electrode pattern, and applying an electrolyte region over a portion of the first electrode pattern and a portion of the second electrode pattern.

Abstract: On the delivery side of a device in which tubular sleeves (25) for battery plates are produced from web-shaped separator material, there is a compartmented star (40) with several compartments (41). After a sleeve (25) has been inserted into the compartment (41), the compartmented star (40) is turned to move the compartment (41) with the sleeve (25) into the insertion position. In the insertion position the sleeve (25) in the compartment (41) is pushed by a stop (52) so far that its insertion-side end is pushed over the legs (56) of the spreading elements (55). Through the end of the sleeve (25) held open by the spreading elements (55) a plate is inserted until it rest against the stop (52). Then the sleeve (25) with the plate pushed into it is pulled out of the compartment (41) laterally by rollers (60) and delivered for further use.

Abstract: A method and apparatus for cold forming a battery terminal having a base and an insert. The insert includes a first portion encapsulated within the base and a second portion that extends beyond a first side of the base.

Abstract: An apparatus for manufacturing a battery electrode from foamed metal electrode material includes first and second rollers which are parallel to each other at a shaft center, and rotatable in directions opposite to each other, and a guide bar which is between the first and second rollers. A method for manufacturing a battery electrode includes supplying a foamed metal electrode material including voids, and having a filled portion filled with active material and an unfilled portion without the active material, and a boundary line between the filled and unfilled portions. Part of the unfilled portion is folded in parallel to the boundary line passing through the unfilled portion, and at right angle against the unfilled portion. A lead welding portion is formed along the direction of the longer side, by applying, to the unfilled bent portion, a force in the direction perpendicular to the filled portion in a way to crush the voids, and compress the bent portion.

Abstract: The invention relates to a bipolar plate for a fuel cell comprising on at least one of its faces at least one flute able to form with the surface of an adjacent electrode at least one gas distribution channel, wherein said distribution channel has a shape or geometry such that the liquid of the biphasic flow flowing in said channel may be moved away from said electrode surface. The invention also relates to a method for preparing such a bipolar plate and to a fuel cell comprising at least one of such bipolar plates.

Abstract: Apparatus for forming flat galvanic elements, wherein a large number of flat cells are inserted next to one another in recesses in a holder, wherein the recesses have been adapted to suit the cross-section of the cells. Conductor tabs on the flat cells point in the same direction and are clamped between contacting springs in the form of plates arranged on holders. The contacting springs contact both sides of the conductor tabs and have contacting surfaces that are much wider than the conductor tabs.

Abstract: Membrane electrode assemblies are described that include an ion conductive membrane a catalyst adjacent to the major surfaces of the ion conductive membrane and a porous particle filled polymer membrane adjacent to the ion conductive membrane. The catalyst can be disposed on the major surfaces of the ion conductive membrane. Preferably, the catalyst is disposed in nanostructures. The polymer film serving as the electrode backing layer preferably is processed by heating the particle loaded porous film to a temperature within about 20 degrees of the melting point of the polymer to decrease the Gurley value and the electrical resistivity. The MEAs can be produced in a continuous roll process. The MEAs can be used to produce fuel cells, electrolyzers and electrochemical reactors.

Abstract: The invention relates to a sleeve separator for a lead plate (2) of a lead-acid accumulator. The sleeve separator surrounds the front and rear sides and lower and bottom edges of said lead plate. The invention is characterised in that the separator material (6) on the top edge of the lead plate (2) and the sleeve is folded away from the lead plate on one side approximately at right angles, so that it projects sideways; in that the separator material (8) on the other, opposite sleeve side is also folded over the upper edge of the lead plate at right angles and also projects sideways from the side of the sleeve; and in that the two separator sections which project sideways at approximate right angles from the side of the sleeve and which are superimposed, are interconnected by a joint (7).

Abstract: Not all gas diffusion structures known to date can guarantee water balance compensation in the fuel cell, protection against drying and prevention of water deposits while simultaneously ensuring even distribution of reaction gases. In the gas diffusion structure, according to the invention, a gradient is produced in terms of gas permeability perpendicular to the membrane by way of a stratified system. This guarantees, at an appropriate operating temperature and appropriate stoichiometry of the reactants, constant and optimal humidification in all points of the membrane by the formed product water. Additional humidification systems can thus be discarded.

Abstract: A positive electrode plate (8), a negative electrode plate (4), and a separator (7) respectively having lengths required for constituting one spiral electrode group (103) are mounted on individual mount jigs (30, 32, 28) for pulling out or for winding, thereby constituting individual cassettes (29, 31, 27). These individual cassettes (29, 31, 27) are sequentially supplied for, and then mounted on a plurality of group winding head units (20) circulating along a predetermined transportation path. The electrode plates (8, 4) and the separator (7) are wound around a rotationally-driven winding shaft (22) of the group winding head unit (20) while the individual electrode plates (8, 4) supplied from the individual electrode plate cassettes (29, 31) are being positioned at predetermined relative positions on both sides of the separator (7) supplied from the separator cassette (27) in a process for circularly transporting the group winding head units (20).

Abstract: A device for manufacturing lead plates for a lead/acid battery, wherein lead electrode grates are filled with an active paste to form green lead plates to be cured, has at least three climate-controlled, connected chambers for curing the green lead plates. An inlet for introducing the green lead plates into a first one of the climate-controlled chambers is provided. The device has a transport device for moving the lead plates through the at least three climate-controlled chambers for curing. A removal device for removing the cured lead plates is provided. A control device controls temperature, humidity, and air movement in the at least three climate-controlled chambers.

Abstract: The invention relates to an improved apparatus and method for assembling a battery. The invention includes an improved apparatus and method for sealing a battery case closure to a battery case. The apparatus comprises a device for moving a carrier with fluid pressure through fluid conduits disposed internal a shaft. A novel case stop is disclosed for stopping and positioning a battery case on a support. A method is disclosed for heating a battery case with a case heater. A conveyor system is included for sequentially moving a plurality of flat battery components such as case closures.

Abstract: A unique discontinuous cathode sheet structure is incorporated within thin-film electrochemical halfcells and full cells. A thin-film electrochemical cell structure includes a cathode sheet layer comprising a series of discontinuous cathode sheets. In a monoface configuration, each of the cathode sheets includes one cathode layer in contact with a current collector layer. In a biface configuration, each of the cathode sheets includes a pair of cathode layers each contacting a current collector layer. A gap is defined between adjacent ones of the cathode sheets. A solid electrolyte layer contacts a surface of one or both cathode layers, depending on the configuration, and extends across the gaps defined between the adjacent cathode sheets. The cathode sheets may be arranged in a number of rows to define a matrix of the cathode sheets.

Abstract: A lug brushing assembly (10) that brushes the lugs of battery plates in an in-line manner so as to eliminate extra battery plate handling procedures. The lug brushing assembly (10) more effectively cleans the lugs of battery plates without causing excessive wearing of the brushes or abrasion on the lugs.

Abstract: A fixture, for liquid electrolyte impregnation of an electrochemical cell, includes a base on which a cap is removably provided. The base includes a nest that receives the electrochemical cell. The cap includes a fill port in communication with the nest. In order to impregnate the cell, a vacuum is created in the nest via the fill port. Subsequently, the electrolyte is injected through the fill port and into the nest. The vacuum may be applied via the fill port, or alternatively, a vacuum port may be provided in the cap through which the vacuum is applied.

Abstract: An apparatus is provided for performing in-line extraction, activation and sealing of a lithium polymer (LiPo) battery. The apparatus includes a pair of nosepieces that are inserted into opposing, open sides of the battery. A pair of clamp and seal arrangements associated with each nosepiece are moved from an insertion position to a clamp/seal position wherein outer packaging of the battery is sealed against an outer, convex surface of the nosepieces. Thereafter, an extraction fluid, such as heated, dry air or an inert atmosphere may be drawn through the battery, the nosepieces providing access to the interior of the battery, to thereby effect extraction. Thereafter, an electrolyte may be drawn into the interior of the battery using the nosepieces. A pair of sealing bars seal the open sides of the packaging.

Abstract: A method of constructing a battery using a control unit to cause pallets on an automated conveyor system to move between indexed positions on the conveyor system. Control unit causes terminals to be deposited on said pallet in a first position, control unit causes pallet to be moved to a second position, and a delivery mechanism controlled by control unit deposits bicells on said terminals with use of an alignment plate, said alignment plate on a separate circulating conveyor, controlled by control unit. Bicells are aligned to be in electrical contact with said terminals.

Abstract: The method for producing plates for batteries according to the present invention comprises: allowing X-rays to penetrate through a supplied core material, thereby calculating the weight of the core material; filling the core material with an active material; then again allowing X-rays to penetrate through the core material, thereby calculating the weight of the filled active material and the core material; calculating the weight of the active material based on the difference in these weights measured; if this weight of the filled active material deviates from a given weight, adjusting the amount of the active material to be filled in the core material, thereby inhibiting variation in the amount of the filled active material; and then drying the core material filled with the active material to make an electrode plate.

Abstract: In a process and an apparatus for fabricating a solid electrolytic capacitor comprising a capacitor element including an anode member provided with a chemical conversion coating and an electrically conductive polymer serving as a cathode electrolyte and impregnating the capacitor element, an agitating station 7 is provided between a mixing station 5 and an impregnating station 6 to have a mixture of a monomer and an oxidizer agitated immediately before the step of impregnating the capacitor element with the mixture to render the mixture uniform. The mixture can be agitated, for example, by an air injection nozzle disposed at the agitating station 7 for injecting compressed air into the mixture. This affords solid electrolytic capacitors with diminished variations in electrical characteristics.

Abstract: In the process of manufacturing a cylindrical battery, when a tubular separator (3) and bottom separator (5) are inserted into a battery casing (1) in which are accommodated positive electrode mixture pellets (2), by inserting the bottom separator (5) such that it is pushed into the battery casing (1) at the leading end of the tubular separator (3), the peripheral portion of the bottom separator (5) is raised up, so that both separators (3,5) are inserted into the battery casing (1) in a condition with the leading end of the tubular separator (3) surrounded from the outside by this peripheral raised-up portion.

Abstract: A method of manufacturing a lithium secondary cell capable of preventing an active material layer from oxidation and moisture absorption is obtained. This method of manufacturing a lithium secondary cell comprises steps of forming an active material layer on a collector by a method supplying raw material through discharge into a vapor phase and holding the collector formed with the active material layer at least under an inert atmosphere or under a vacuum atmosphere up to preparation of the cell. Thus, the collector formed with the active material layer is prevented from exposure to the atmosphere, whereby the active material layer is prevented from oxidation and moisture absorption. Consequently, a lithium secondary cell having excellent characteristics can be prepared.

Abstract: An improved apparatus and method for making lead-acid storage battery plates comprising an alignment puncher for creating a plurality of alignment holes in a lead strip as the lead strip is progressively expanded and cut into a grid like pattern on an expander die system. The alignment of the lead strip is accomplished by inserting at least one alignment pin into at least one of the plurality of alignment holes that have been punched into the lead strip as the lead strip is progressively expanded and cut into a plurality of wire-like segments along opposing edges of the lead strip. After each cut, the alignment pin retracts while the lead strip is indexed.

Abstract: A polymer battery module (2) provided with tabs (4) is put in a package (5) and an open end part of the package (5) is heat-sealed by a heat-sealing machine (10). The heat-sealing machine (10) is provided with a pair of sealing heads (10a, 10b) respectively having sealing surfaces (12). The sealing surfaces (12) of the sealing heads (10a, 10b) are provided with recesses (11) in parts thereof corresponding to the tabs (4) of the polymer battery module (2) contained in the package (5) as located in place between the sealing heads (10a, 10b) for heat-sealing.

Abstract: A method of fabricating electrochemical cells and batteries wherein the successive anode and cathode layers are separated by a polymeric electrolyte layer having a protruding polymer edge around its perimeter which reduces the likelihood of inadvertent contact between the anode and cathode current collectors is provided. The polymer edge functions as a non-conducting physical barrier positioned between adjacent current collectors. An apparatus for preparing electrochemical cells is also disclosed.

Abstract: The invention relates to an improved apparatus and method for assembling a battery. The invention includes an improved apparatus and method for sealing a battery case closure to a battery case. The apparatus comprises a device for moving a carrier with fluid pressure through fluid conduits disposed internal a shaft. A novel case stop is disclose for stopping and positioning a battery case on a support. A method is disclosed for heating a battery case with a case heater. A conveyor system is included for sequentially moving a plurality of flat battery components such as case closures.

Abstract: A battery housing including a cover that has one or more semi-rigid legs depending outwardly therefrom, and the battery housing also including a battery tray for selectively receiving one or more batteries and one or more flexible circuits. The battery tray has one or more fixtures that provide access to at least one battery and at least one flexible circuit such that the flexible circuit can be spot-welded to the battery, and each fixture is placed about the battery tray whereby each of the one or more legs of the cover snap-fits into a fixture and such action preferably affixes the cover to the battery tray to form the battery housing.

Abstract: Systems and methods for producing a multilayer thin film energy storage device having a plurality of thin film battery cells arranged to provide a higher output than a single cell thin film battery. The thin film battery cells are configured so that they stacked one on another with at least one thin film battery cell positioned upside down on top of another thin film battery cell. Alternatively, the thin film battery cells may be arranged in a side-by-side configuration. Each thin film battery cell includes a thin film layer of cathode material and anode material with an electrolyte material disposed between and separating the cathode material and anode material. A thin film current collector is positioned adjacent to each cathode and anode thin film layer. The particular pattern of thin films of current collectors, anodes, electrolytes and cathodes serves to a provide a high output necessary for particular applications.

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.