Abstract: Improvements in the end block design for zinc/bromine batteries include modification of the end block configuration which previously has included rigid resin covers and end block plates with a honeycomb structure sandwiched therebetween. Such prior structures were used adjacent to terminal electrode frames. In the present invention, the terminal electrodes are preferably contained within the end plate, thereby eliminating two components used in prior zinc/bromine battery design and the end block itself is formed from two components by building a rib structure into the plate and cover and welding the two components together to join the ribs and form an integral and structurally sound unit. The end block configuration could be used for bipolar lead-acid batteries or other types of flowing or non-flowing batteries or capacitors.

Abstract: An electrochemical cell stack is made from a continuous laminate web including an electrode layer, an electrolyte layer, and a plurality of discrete opposite polarity electrode segments. The laminate is fan-folded into a stack such that substantially the entire surface area of the opposite polarity electrode segments are in contact with the electrolyte layer and in ion exchange with the electrode layer. Current can collected from the discrete opposite polarity electrode segments by opposite polarity electrode current collector strips that electrically connect the opposite polarity electrode segments. A method for making an electrochemical cell stack is also disclosed.

Abstract: Flat pack rechargeable batteries which include internal support members are disclosed. In the most preferred form of the invention, an intermediate support extender plate is provided. The plate also includes holes to maintain a common path for electrolyte.

Abstract: A zinc secondary battery in which a plurality of battery cells are separated by bipolar plates which provide electrical conductivity between the cells and in which the battery cells and bipolar plates are arranged horizontally in a vertical stack.

Abstract: A battery comprises a stack of electrochemical cell units (1) each comprising a positive electrode (2), a solid electrolyte (3) and a negative electrode (4), the electrodes of the cell units being interconnected by means of a plurality of connector devices (7, 8) each comprising a base section (7a, 8a) connected to an electrode and a pair of contact sections (7c, 8c) extending from the cell unit, the devices (7, 8) being arranged in two stacks with the pairs of contact sections (7c, 8c) of the devices in each stack overlying one another to form two sets of contact sections, adjacent contact sections (7c, 8c) of each set being interconnected with successive interconnections throughout each stack of connector devices alternating between the two sets of contact sections. Unit cells may be connected in parallel or series. Connector devices (7, 8) of opposite polarity may be provided symmetrically either side of a centerline about which the unit cell (1) can be rotated 180.degree.

Abstract: Two metallic foils each have a continuous band of polyethylene film adhesively bonded thereto. The lithium battery is sandwiched between these two metallic foils and a thermo-seal is provided to join the two polyethylene films. This construction prevents any outside substance from contacting the lithium battery.

Abstract: The preferred embodiment of the present invention relates to a sealed, oxygen recombinant lead-acid battery which includes a series of modules, e.g. 4-volt modules. The modules are prepared from frame and film assemblies which are easily stacked to the desired voltage or capacity. In the preferred embodiment, the assemblies include two 2.0 normal voltage cells, attached in series, three of which are then combined to form a 12-volt system. Modularity eliminates the need for expensive tooling and parts inventory and permits the creation of a wide variety of battery designs. Specially designed vents are employed to permit gas escape during overcharge or if recombination efficiencies are less than desired and to prevent entry of oxygen or moisture when the battery is in its recombinant mode.

Abstract: An electrochemical device comprises a plurality of cells, each cell including a laminate cell membrane, made up of a separator/electrolyte means interposed between alternating positive and negative electrodes, each type of electrode being respectively in common contact to a single current collector.

Abstract: Improved nickel-hydrogen batteries (10) are disclosed, wherein the improvement provides for wettable porous polypropylene cloth gas diffusion screens (12) to separate the individual cells (16) thereof. When necessary, substantially all of the electrolyte may be readily drained from the cells (16) of the batteries (10). Wettability is achieved by oxidizing the surfaces of the cloth gas diffusion screens (12) prior to assembling them in the batteries (10).

Abstract: There is disclosed a process for laminating a metal-based anode member to one side of a conductive intermediate layer and an argentic oxide-containing layer to the other side thereof and using a plurality of such bipolar electrodes in a battery assembly defining a compartment for passage of an alkaline medium, such as seawater, or alkali.

Abstract: An apparatus [10] is disclosed for a lightweight bipolar battery of the end-plate cell stack design. Current flow through a bipolar cell stack [12] is collected by a pair of copper end-plates [16a,16b] and transferred edgewise out of the battery by a pair of lightweight, low resistance copper terminals [28a,28b]. The copper terminals parallel the surface of a corresponding copper end-plate [16a,16b] to maximize battery throughput. The bipolar cell stack [12], copper end-plates [16a,16b] and copper terminals [28a,28b] are rigidly sandwiched between a pair of nonconductive rigid end-plates [20] having a lightweight fiber honeycomb core which eliminates distortion of individual plates within the bipolar cell stack due to internal pressures. Insulating foam [30] is injected into the fiber honeycomb core to reduce heat transfer into and out of the bipolar cell stack and to maintain uniform cell performance.

Abstract: Electrochemical cells containing lithium and a solid polymer electrolyte in the form of thin films are produced by making multilayer assemblies from double-layer solid polymer electrolyte/composite positive electrode sub-assemblies which are subsequently associated with the other constituent layers of the cell so that the multilayer assembly so obtained comprises a layer of a metal of low ductility. Cells may be made from multilayer assemblies by stacking, rolling or bending techniques.

Abstract: Described herein is a contact arrangement for a battery cell of a galvanic battery. The battery cell comprises a positive mass layer (6, 106) and a negative electrode layer (11, 111). A separator layer (5, 105) separates the positive mass layer (6, 106) and the negative electrode layer (11, 111) from each other. A positive current collector (7, 107) is connected to the positive mass layer (6, 106). A case (1, 2, 101, 102) made of an insulating material hermetically encloses the active components of the battery cell. Contact units (12, 14, 16, 22, 23, 24, 116) create electrical contact through the case (1, 2, 101, 102) with the positive current collector (7, 107) and with the negative electrode layer (11, 111), respectively. An additional insulation layer (9, 13, 113) made of a tough and adhesive material and bounded by the case (1, 2, 101, 102) is provided so as to maintain the hermetic nature of the case despite the passing-through of a contact unit (12, 14, 16, 22, 23, 24, 116).

Abstract: A light weight deflection-resistant end block is provided for a battery and comprises a base member of a light weight, chemically inert and electrically resistive material which has one or more cavities adapted to receive low density, substantially rigid inserts such as honey-combed aluminum.

Abstract: In an electric cell stack assembly, each cell (1) in the top cell stage of the stack abuts against a holder member (7) in the very top stage of the stack having substantially the same mechanical characteristics, relative to a cell of the top cell stage, as has each cell relative to a cell of the next lower stage in the stack. Reinforcing members (8, 9) run along the entire length of the stack, including the said very top stage. The assembly is inserted in a tube and is encapsulated in a compound which preferably has a useful temperature range extending from -55.degree. C. or less to +250.degree. C. or more.

Abstract: A method of manufacturing a battery consisting of one or several cells piled on each other and integrally connected along their circumferences. Each cell comprises a zinc anode, an alkaline electrolyte, a cathode of mercuric oxide, silver oxide or manganese dioxide or a mixture thereof, and a cell casing in the form of a plastic cup. A terminal plate is located on both sides of the plastic cup, said terminal plates abutting a substantial area of the outer and the inner side of the bottom, whereby at least one terminal plate comprises at least one projecting knob extending through a comparatively small aperture in the bottom of the cup and being connected by spot welding to the second terminal plate in such a manner that the plates sandwich and under pressure abut the material in the bottom of the cup. Prior to the spot welding a mass is added in the form of bitumen to the aperture in the bottom of the cup, the sealing mass being pressed sideways during the spot welding.

Abstract: A terminal pattern is disclosed for an assembly of reactive metal electrochemical cells which includes a plurality of bipolar electrodes arranged in stacked, spaced relationship and connected in series between a pair of spaced conductive end plates. The terminal pattern on each end plate of the assembly includes an array of interconnected terminal segments of high conductive material disposed outwardly of a center point of the respective end plate in a generally uniform pattern with respect to the area configuration of the end plate. The pattern of terminal segments enlarge the terminal area and provide more uniform current distribution and active metal consumption over the areas of the bipolar electrodes.

Abstract: The present invention concerns an electrochemical generator with a lithium anode and liquid cathode and, notably, generators using the Li/SO.sub.2, Li/SOCl.sub.2 and Li/SO.sub.2 Cl.sub.2 couples. This generator comprises of stack of flat elements threaded onto rods, one end of each rod being attached to the cover of a case. The anodes are threaded by flexible lugs which act as current collectors and fuses.

Abstract: A lithium alloy/metal sulfide battery as a dipolar battery is disclosed with an array of stacked cells with the anode and cathode electrode materials in each cell sealed in a confining structure and separated from one another except across separator material interposed therebetween. The separator material is contained in a module having separate perforated metallic sheets that sandwich opposite sides of the separator material for the cell and an annular insulating spacer that surrounds the separator material beyond the perforations and is also sandwiched between and sealed to the sheets. The peripheral edges of the sheets project outwardly beyond the spacer, traverse the side edges of the adjacent electrode material to form cup-like electrode holders, and are fused to the adjacent current collector or end face members of the array.

Abstract: A leak detector employing an ion-conducting membrane is disclosed. An oxygen-ion conducting membrane which employs a high vacuum on one side is used to detect very small quantities of oxygen flowing through a minute fissure in a part to be tested for leaks. The oxygen-ion conducting membrane is biased with direct current voltage to drive oxygen-ions through the membrane away from the high vacuum side.

Abstract: A process of making laminar electrical cells and batteries each having an end terminal comprising a thin sheet of metal, in which an elongated web is made by adhering the end terminals to a sheet of dimensionally stable thermal insulating material in a spaced rectangular array of rows and columns. The process of forming pockets in the end terminals and registering the pocketed terminals on a second web carrying a spaced rectangular array of battery components comprising the steps of forming index perforations in each terminal, deforming the terminals to provide pockets therein, and joining the terminal web and the second web with the aid of the index perforations.

Abstract: Laminar electrode subassemblies comprising a lithium layer having one surface consisting essentially of metallic lithium adhered to a conductive plastic substrate, and a method of making such subassemblies in which a web of lithium foil having at least one freshly exposed surface is laminated directly to a conductive plastic substrate without an intermediate layer of conductive plastic adhesive.

Abstract: Laminar electrical cells and batteries, each cell of which comprises a first electrode formed as a porous layer of electrochemically active particles on an electrically conductive, electrochemically inactive substrate coextensive with the particle layer. The electrochemically inactive substrate is adhered around its periphery to the borders of an aperture in an electrically insulating frame. A separator for each cell overlies the active particle layer of the first electrode and has borders extending beyond the borders of the first electrode and within the borders of the insulating frame. A second electrode for each cell comprises a slurry of electrochemically active particles in contact with the other side of the separator. Methods of making the above cells and batteries from elongated webs of electrically insulating ones of the constituent materials of the cells.

Abstract: Electrical cells and batteries having lithium anodes and cathodes comprising an organic slurry of MnO.sub.2 and carbon particles in an organic solvent in contact with a conductive plastic current collector, and a method of making the cathodes comprising the steps of heating MnO.sub.2 to remove absorbed and adsorbed water and water of crystallization, cooling the dehydrated MnO.sub.2, dispersing the cooled and dehydrated MnO.sub.2 in an anhydrous solvent to form a slurry, depositing the slurry in discrete cathode patches on cell component substrates, and sealing the slurry patches into cells having substantially gas impervious cell enveloping boundaries.

Abstract: A low maintenance battery comprises a sealed casing (102) having a cavity (204) receiving a stack (108) of monopolar and bipolar plates (110, 112) interspersed with mats (122) of fiberglass felt immobilizing electrolyte and forming a gas path for diffusion of oxygen to the negative electrode (112). The casing contains a single, resealable vent (202). During charging, oxygen generated at the positive plate (110) diffuses through the mat (122) and decomposes at the negative plate (112). The negative plate (112) has a larger capacity than the positive plate (110) to prevent evolution of hydrogen. Voltage potential is increased or decreased by placing one or more bipolar plates (120) in series relation between alternating positive and negative monopolar plates that are connected in parallel to respective positive and negative battery terminals (104, 106). The monoplates (110, 112) are connected in parallel to respective positive and negative battery terminals (104, 106) by way of bus plates (114, 116, 130, 132).

Abstract: Laminar electrical cells and batteries, each cell of which comprises a first electrode formed as a porous layer of electrochemically active particles on an electrically conductive, electrochemically inactive substrate coextensive with the particle layer. The electrochemically inactive substrate is adhered around its periphery to the borders of an aperture in an electrically insulating frame. A separator for each cell overlies the active particle layer of the first electrode and has borders extending beyond the borders of the first electrode and within the borders of the insulating frame. A second electrode for each cell comprises a slurry of electrochemically active particles in contact with the other side of the separator. Methods of making the above cells and batteries from elongated webs of electrically insulating ones of the constituent materials of the cells.

Abstract: Laminar batteries of series connected cells comprising lithium anodes and an electrolyte containing a passivating solvent reactive with lithium in which the cells are electrically connected in series by intercell barriers comprising outer layers of electrochemically inert electronically conducting material in contact with the electrochemically active anode and cathode of adjacent cells and a layer of metal foil between the electrochemically inert layers.

Abstract: A relatively thin, flat or planar battery is disclosed which includes one or more cells in series relationship each comprising a planar anode in superposed relationship with a planar cathode and a separator disposed intermediate and extending substantially coextensive the facing surfaces of the anode and cathode possessing marginal portions and an aqueous electrolyte permeable central portion. Each cell includes an aqueous electrolyte disposed in the central portion of the separator and in contact with the facing surfaces of both the anode and the cathode and an electrically nonconducting, sealant extending intermediate and providing adhesive contact between the marginal portions of the separator and next adjacent facing surfaces. Each battery is designed to include a planar anode and/or cathode next adjacent a surface of the battery which electrode includes a conductive metal sheet; a gas permeable, water-vapor impermeable plastic sheet and an electrochemically active negative or positive material.

Abstract: Disclosed are maintenance-free cells and batteries of the lead/acid type which have improved deep cycle life. The plates are flat and are oriented horizontally as a stack in a cell which contains unabsorbed free electrolyte. The free electrolyte wets but does not cover the top surface of at least one negative plate. The vertical dimension of the plate stack must not exceed one-half its major horizontal dimension.

Abstract: Laminar electrical cells and batteries of the Leclanche type, in which the electrolyte comprises an aqueous solution containing from about 18 to about 22 percent of NH.sub.4 Cl and from about 25 to about 40 percent of ZnCl.sub.2 by weight, based on the weight of solution. The electrolyte may contain a gelling agent, and may initially contain a minor amount of mercuric chloride.

Abstract: A laminar battery comprising an end terminal formed with a pocket to accept internal components without requiring additional edge thickness in the seal area, incorporating as the separator in at least the cell immediately adjacent the pocketed end terminal a layer of cellophane together with a layer of paper on the side of the cellophane confronting the cathode.

Abstract: Electrical energy is stored in a device formed of electrodes coupled with an oxidation-reduction polymer material, such as a polymer of quinone, semiquinone and hydroquinone units, when a current is supplied to the device to create a charge gradient thereacross with units at the positive end being oxidized and units at the negative end being reduced. The charge gradient across the electrical storage device is increased by arranging a plurality of electrically conductive barrier laminations made of a material preventing ion passage therethrough in the oxidation-reduction polymer material to create separated regions of reduced and oxidized functional groups producing an additive charge gradient.

Abstract: Laminar electrical cells and batteries of the LeClanche type especially adapted for service at high drain rates with variable duty cycles by the inclusion of cathodes formed as slurries of MnO.sub.2 and carbon particles in an electrolyte comprising, by weight, about 2% of NH.sub.4 Cl, about 25% ZnCl.sub.2, and the balance water with a minor amount of mercuric chloride.

Abstract: An electrochemical cell having two electrodes of opposite polarity cooperating with an electrolyte solution to produce an electrical potential there between during normal operation, configured to minimize explosions upon forced discharge or charging by locating at least a portion of one electrode in close proximity to the other electrode such that a low impedance path is created between the two electrode surfaces whereby the quantity of externally imposed current flowing through the main body of the cell is minimized. In a preferred embodiment, portions of the two electrodes have contiguous surfaces spaced from each other by a porous separator material with the surfaces chosen to allow plating dendritic growth from one electrode to the other at potential differences below that at which electrolysis occurs.

Abstract: An electrochemical cell having two electrodes of opposite polarity cooperating with an electrolyte solution to produce an electrical potential there between during normal operation, configured to minimize explosions upon forced discharge or charging by locating at least a portion of one electrode in close proximity to the other electrode such that a low impedance path is created between the two electrode surfaces whereby the quantity of externally imposed current flowing through the main body of the cell is minimized. In a preferred embodiment, portions of the two electrodes have contiguous surfaces spaced from each other by a porous separator material with the surfaces chosen to allow plating dendritic growth from one electrode to the other at potential differences below that at which electrolysis occurs.

Abstract: A battery comprises a single flat cell with a cell casing in the form of a plastic cup, or several cells piled on each other, whereby the plastic cups are integrally connected along the circumference. Each plastic cup comprises a terminal plate located both on the inner side and on the outer side of the bottom of each cup. One of these terminal plates comprises a projecting knob extending through an aperture in the bottom of the cup, and is connected to the other terminal plate in such a manner that the plates squeeze tightly about the bottom of the cup and abut the upper and lower surfaces thereof by a permanent pressure. As a result, a durable, efficient sealing against electrolyte leakage at the terminal passage in the bottom of each plastic cup is provided.

Abstract: A vent for thin, flat laminar batteries comprising a paper strip enclosed along its length by a gas-permeable, liquid impermeable thermoplastic composition. One or more of the vents can be incorporated into a frame structure which also serves to provide internal and external sealing. For this purpose, the vents are sealed to frames comprising closed loops of thermoplastic material, dimensioned to correspond to the external and internal dimensions of the battery. Methods of making vents comprising the steps of laminating paper with a thermoplastic material and forming the laminate into thermoplastic tubes filled with a paper core.

Abstract: The method of making a thin flat laminar battery comprising the steps of coating a substrate with a dispersion of zinc powder and water to produce an anode slurry, and thereafter diffusing electrolytes into said anode slurry; and electrical cells and batteries made by this process.

Abstract: The invention relates to a method for the manufacture of an electrochemical cell or battery, consisting of a stack of plate-shaped elements, each of which consists of a sheet or plate of electrode material which is mounted in a frame made of electrically insulating fibrous-web material impregnated with a non-polymerized thermosetting synthetic material, which elements in a first compression molding stage are heated under pressure for a relatively short primary time at a relatively low primary temperature under which conditions the thermosetting synthetic material flows well but polymerizes only to a minor degree, thereafter the elements are combined with other battery components are stacked into an electrochemical cell package which in a second compression molding stage is formed into a coherent block by compression for a relatively long secondary time and at a relatively high secondary temperature to set the thermosetting synthetic material.

Abstract: A relatively thin, flat or planar battery is disclosed which includes one or more cells in series relationship each comprising a planar anode in superposed relationship with a planar cathode and a separator disposed intermediate and extending substantially coextensive the facing surfaces of the anode and cathode possessing marginal portions and an aqueous electrolyte permeable central portion. Each cell includes an aqueous electrolyte disposed in the central portion of the separator and in contact with the facing surfaces of both the anode and the cathode and an electrically nonconducting polyacrylate sealant extending intermediate and providing adhesive contact between the marginal portions of the separator and next adjacent facing surfaces.

Abstract: A bipolar battery is provided which comprises at least two battery cells, said battery cells each comprising a plurality of electrodes, said electrodes comprising at least two cellular end plate electrodes and at least two interstitially located single pole electrodes, a continuous, sheet-like insulator located in alternating, woven disposition within each of said cells between all adjacent electrodes to provide electrical separation thereof, wherein the end plate electrodes of adjacent cells are of opposite polarity and comprise a single, bipolar electrode, and all of said electrodes are adapted to conduct current internally between each other and said cells.

Abstract: A laminar battery capable of providing multiple currents and capacities at different voltages, in which electrical access is provided to intermediate cells in the battery by conductive metal terminal layers incorporated in the structure of the battery.

Abstract: A power module assembly in the form of an electrochemical battery which is composed of a plurality of anode-cathode units arranged in stacked relation within a housing. It is necessary that the anodes and cathodes be tightly pressed together at all times so that as an electrolyte flows therebetween there will be the desired electrochemical reaction. This is accomplished by a pressure device. Since the anodes are consumable, as the anodes are consumed it is necessary that the stack be compressed to that the same pressure may be maintained between the anodes and cathodes. Accordingly, the pressure device is capable of expanding and at the same time transmitting constant pressure on the stack.

Abstract: A relatively thin, flat or planar battery which includes one or more cells, each cell having a planar anode in superposed relationship with a planar cathode and a separator disposed intermediate and extending substantially coextensive the facing surfaces of the anode and cathode and possessing an aqueous electrolyte solution disposed in the central portion of the separator. The end cell anode comprises a zinc sheet carrying a coating of zinc particles wherein both the sheet and the particles are in contact with the electrolyte.

Abstract: Thin flat electrical cells and batteries comprising frames formed with a central opening for receiving wet electrical cell components and made from a two layered structure of a high melting thermoplastic material and a lower melting thermoplastic material, and methods of making the same.

Abstract: Thin flat electrical cells and batteries comprising frames formed with a central opening for receiving wet electrical cell components and made from a two layered structure of a high melting thermoplastic material and a lower melting thermoplastic material, and methods of making the same.

Abstract: A laminar triplex structure for use in the manufacture of electrical cells and batteries, cells and batteries made therefrom, and methods of making the same. The laminate comprises a thin flat sheet of separator material, a layer of metallic particles on one surface of the separator sheet and adhered thereto with a binder, and a layer of conductive plastic adhered to the layer of metal particles. The laminate is made by the process of coating a dispersion of metal particles in a solution of a polymeric binder in an organic solvent over the separator, drying to remove the solvent, coating over the dried metal layer with a dispersion of conductive particles in a solution of a polymer in an organic solvent, and drying to remove the solvent.

Abstract: A flat battery structure and method of fabricating it which is characterized in the utilization of an electrically insulative carrier web base in combination with discretely positioned electrically conductive components of the battery pile structure. Through the select dimensioning of the discrete components of the battery, in conjunction with the utilization of insulative web carriers, improved reliability of battery operation is realized.

Abstract: A planar primary battery particularly suited for photographic application characterized in exhibiting high current drain capacities and improved manufacturability. The battery structure incorporates at least one electrode present in aqueous slurry form as a particulate dispersion of active material and poly(2-acrylamido-2-methylpropanesulfonic acid) in combination with electrolyte.

Abstract: A method of sealing a laminar battery in which the central region of the battery is cooled and held under pressure while the peripheral regions of the battery are heated under the same or a lower pressure. The thicknesses of the materials are chosen so that the completed battery is substantially as thick at the edges as in its central regions.