Having Coating In The Pores Patents (Class 429/236)
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Publication number: 20070207388Abstract: A method of producing an electrode includes the steps of filling an active material in an electrode substrate made of woven or non-woven fabric having its fiber surface coated with metal, and pressing the electrode substrate to obtain an electrode, wherein the pressing is performed using the electrode substrate having a thickness of less than 2.0 t when the thickness of the electrode after the pressing is t. This ensues that the electrode substrate has a thickness allowing the active material of a sufficient amount to be filled therein, and a battery electrode in which the filled active material is unlikely to peel off from the electrode substrate can be produced. Accordingly, a battery electrode having a desired thickness and desired capacity and that can suppress degradation in battery performance due to repeated charge and discharge, and its producing method are provided.Type: ApplicationFiled: March 1, 2007Publication date: September 6, 2007Inventors: Kazuki Okuno, Keizo Harada, Masahiro Kato, Tetsuo Sakai, Tsutomu Iwaki, Masaru Yao
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Patent number: 7252907Abstract: A nonaqueous electrolyte secondary battery including positive and negative electrodes capable of occluding and releasing lithium and a nonaqueous electrolyte and in which the negative electrode includes a foamed metal containing silicon as an active material therein.Type: GrantFiled: February 26, 2004Date of Patent: August 7, 2007Assignee: SANYO Electric Co., Ltd.Inventors: Masanobu Takeuchi, Seiji Yoshimura
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Patent number: 7195842Abstract: In an electrode for a lithium battery having a lithium storing and releasing active thin film provided on a current collector, such as a microcrystalline or amorphous silicon thin film, the electrode is characterized in that the thin film is divided into columns by gaps formed therein in a manner to extend in its thickness direction and that the columnar portions are at their bottoms adhered to the current collector.Type: GrantFiled: October 20, 2000Date of Patent: March 27, 2007Assignee: Sanyo Electric Co., Ltd.Inventors: Masahisa Fujimoto, Shin Fujitani, Masaki Shima, Hiromasa Yagi, Hisaki Tarui, Hiroshi Kurokawa, Shigeki Matsuta, Yoichi Domoto, Yoshio Kato, Hiroshi Nakajima, Hiroaki Ikeda, Kenji Asaoka, Ryuji Ohshita
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Patent number: 7169509Abstract: This invention provides an electrode comprising a porous conductive substrate as well as an electrode active material and a conductive auxiliary filled in the pores in the substrate. This electrode exhibits improved shape stability (strength), a lower resistivity and better response. This electrode can be used to provide an electrochemical cell capable of quick charge/discharge and exhibiting improved cycle properties.Type: GrantFiled: March 19, 2004Date of Patent: January 30, 2007Assignee: NEC Tokin CorporationInventors: Tomoki Nobuta, Hiroyuki Kamisuki, Masaya Mitani, Shinako Kaneko, Tetsuya Yoshinari
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Patent number: 7105252Abstract: A method for forming a corrosion resistant electrode for a battery includes supplying an electrode for use in the battery and exposing the electrode to an environment including vaporized carbon. At least some of the carbon from the environment may be transferred to the electrode.Type: GrantFiled: April 25, 2003Date of Patent: September 12, 2006Assignee: Firefly Energy, Inc.Inventors: Kurtis C. Kelley, Steven C. Taylor
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Patent number: 7083877Abstract: An all solid state battery comprising: (a) a positive electrode current collector layer, (b) a positive electrode active material layer carried on the positive electrode current collector layer, (c) a negative electrode current collector layer, (d) a negative electrode active material layer carried on the negative electrode current collector layer, (e) a solid electrolyte layer interposed between the positive and negative electrode active material layers, and (f) a substrate carrying either of the positive and negative electrode current collector layers, the substrate comprising a metal sheet and a coating layer covering the surface of the metal sheet, the coating layer comprising at least one metal nitride layer.Type: GrantFiled: June 11, 2003Date of Patent: August 1, 2006Assignee: Matsushita Electric Industrial Co., Ltd.Inventors: Kazuya Iwamoto, Shuji Ito
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Patent number: 7060391Abstract: A battery, a battery electrode structure, and methods to make the same. The product and method comprise applying a layer of lead-tin containing alloy to substrates for anodes or cathodes for lead-acid batteries, in which the substrates are porous or reticulated.Type: GrantFiled: March 26, 2004Date of Patent: June 13, 2006Assignee: Power Technology, Inc.Inventors: Elod Gyenge, Joey Jung, Alvin A. Snaper
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Patent number: 7033702Abstract: A matted particulate electrode located between the current collector and a porous separator of a rechargeable lithium battery is described, which contains electro-active particles intermixed with pliable, solid, lithium ion conducting, polymer electrolyte filaments having adhesive surfaces. The electro-active particles and the optionally added electro-conductive carbon particles adhere to the tacky surface of the adhesively interlinking polymer electrolyte filaments. The matted particulate electrode is impregnated with an organic solution containing another lithium compound. In a second embodiment the porous separator is coated on at least one of its faces, with polymer electrolyte having an adhesive surface and made of the same polymer as the electrolyte filaments. The polymer electrolyte filaments in the matted layer may adhere to the coated surface of the separator.Type: GrantFiled: September 3, 2004Date of Patent: April 25, 2006Assignee: Electrovaya Inc.Inventors: Sankar Dasgupta, James K. Jacobs, Rakesh Bhola
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Patent number: 7033703Abstract: A composite material including a first carbon foam structure including a network of pores and a second carbon foam structure including a network of pores. An intermediate bonding structure is disposed at least in part between the first and second carbon foam structures.Type: GrantFiled: December 20, 2002Date of Patent: April 25, 2006Assignee: Firefly Energy, Inc.Inventors: Kurtis C. Kelley, Charles F. Ostermeier, Matthew J. Maroon
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Patent number: 6994737Abstract: This invention is related to a process for preparing polymeric Li-ion cell with high-capacity as well as the cells manufactured with the process. The process produces anode paste with lithium salt and cobalt oxide and sprays the paste onto aluminum current collector to form the anode; produces cathode paste with two lithium-embedded carbon materials and sprays the paste to copper current collector to form the cathode; produces a paste with polyvinylidene fluoride, silicon dioxide (gas phase), o-dibutyl phthalate ester, and acetone and sprays the paste onto a polyester film to form the diaphragm; performs extraction for the cell assembled with said anode, diaphragm, and cathode, welds lugs, immerses the cell into electrolyte to, and packs the cell with aluminum-plastic composite film, and finally performs formation for the cell, so that a polymeric Li-ion cell with high-capacity is accomplished.Type: GrantFiled: June 4, 2004Date of Patent: February 7, 2006Assignee: Hei Long Jiang Zhong Qiang Power-Tech Co., Ltd.Inventors: Zhiguo Fu, Chunsheng Wang, Guopeng Gao, Hongjun Si, Yanmei Mu
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Patent number: 6979513Abstract: A battery having a current collector constructed of carbon foam. The carbon foam includes a network of pores into which a chemically active material is disposed to create either a positive or negative plate for the battery. The carbon foam resists corrosion and exhibits a large amount of surface area. The invention includes a method for making the disclosed carbon foam current collector used in the battery.Type: GrantFiled: March 12, 2004Date of Patent: December 27, 2005Assignee: Firefly Energy Inc.Inventors: Kurtis Chad Kelley, John J. Votoupal
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Patent number: 6972044Abstract: A workpiece, in which a lead is laid on top of a three-dimensional porous metal body, is placed between an ultrasonic horn and an anvil with a lead portion facing the ultrasonic horn. A support is raised so that the lead portion of the workpiece is pressed between the ultrasonic horn and the anvil. While being rotated around a central shaft with a motor, the ultrasonic horn vibrates at a frequency of 20 kHz in the shaft direction. Thus, the workpiece is advanced continuously, so that the lead is bonded ultrasonically to the three-dimensional porous metal body (i.e., metal-to-metal bonding is established). It is possible to provide a battery electrode that can be produced continuously at a lower running cost, reduce the faulty welding with a current collecting plate, and prevent short-circuits.Type: GrantFiled: September 22, 2004Date of Patent: December 6, 2005Assignees: Matsushita Electric Industrial Co., Ltd., Toyota Jidosha Kabushiki KaishaInventors: Hiroshi Inoue, Kiwamu Inui, Mitsugu Takaki, Shinichi Hojioka
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Patent number: 6933077Abstract: A current collector for polymer electrolyte thin film electrochemical cells and an electrochemical generator is disclosed. The current collector comprises a polymer substrate support film having a thickness of between 1 and 15 microns; a conductive metallic layer having a thickness of less than 3 microns, coated by metal vapor deposition onto at least one surface of the polymer substrate film; and a protective metal or metal oxide layer deposited onto the conductive metallic layer, having a thickness of between 5 and 500 nanometer and being electronically conductive.Type: GrantFiled: December 27, 2002Date of Patent: August 23, 2005Assignee: Avestor Limited PartnershipInventors: Anthony Sudano, Richard Laliberté, Martin Simoneau, Michel Parent
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Patent number: 6933071Abstract: A polymer electrolyte fuel cell comprising a polymer electrolyte made of an ion exchange membrane, catalyst layers disposed on both sides thereof and current collectors disposed on the outer sides thereof, wherein a solvent-soluble fluorine-containing polymer (preferably a polymer having a fluorine-containing aliphatic ring structure) having substantially no ion exchange groups, is incorporated in the current collectors. By the above construction, the current collectors can have a high water repellency for a long period of time, and the polymer electrolyte fuel cell can operate at a high output density constantly over a long period of time.Type: GrantFiled: January 24, 2000Date of Patent: August 23, 2005Assignee: Asahi Glass Company, LimitedInventors: Masaru Yoshitake, Yasuhiro Kunisa, Eiji Endoh, Eiji Yanagisawa
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Patent number: 6905797Abstract: A multicell assembly for a redox flow electrolyzer is constituted by alternately stacking pre-assembled elements, typically an electrode subassembly including porous mat electrodes on opposite faces of a conductive plate and a permionic membrane subassembly. Pressure drops in circulating the electrolyte solutions through respective cell compartments, in contact with fluid permeable three-dimensional electrodes in the form of porous mats, are reduced while enhancing evenness of electrolyte refreshing over the whole geometrical cell-area, by defining cooperatively interleaved flow channels in the porous mat electrode. Two interleaved orders of parallel flow channels are defined. All the parallel spaced channels of each order extend from a common orthogonal base channel formed along the respective inlet or outlet side of the electrolyte flow chamber, and terminate short of reaching the base channel of the other.Type: GrantFiled: December 4, 2002Date of Patent: June 14, 2005Assignee: Squirrel Holdings Ltd.Inventors: Barry M. Broman, Andrea Zocchi
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Patent number: 6887623Abstract: An electrode for a rechargeable lithium battery which includes a current collector and a thin film composed of active material that stores and releases lithium and deposited on the current collector, the electrode being characterized in that the current collector has irregularities on its surface and the thin film has spaces extending in a thickness direction of the thin film and configured to increase their width dimensions toward valleys of the irregularities on the current collector surface.Type: GrantFiled: April 9, 2002Date of Patent: May 3, 2005Assignee: Sanyo Electric Co., Ltd.Inventors: Hiroyuki Fujimoto, Hiroko Sanda, Takashi Okamoto, Toyoki Fujihara, Masahiro Iyori, Maruo Kamino, Shigeki Matsuta
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Patent number: 6887511Abstract: A method for preparing an electrode material for a lithium battery, characterized in that a noncrystalline silicon thin film that serves as an active material is deposited on a substrate.Type: GrantFiled: October 20, 2000Date of Patent: May 3, 2005Assignee: Sanyo Electric Co., Ltd.Inventors: Masaki Shima, Hiromasa Yagi, Hisaki Tarui, Hiroaki Ikeda, Masahisa Fujimoto, Shin Fujitani, Yoichi Domoto
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Patent number: 6878173Abstract: A battery electrode plate (19) is produced via an active material impregnation step for impregnating an entire porous core substrate shaped like a thin plate (1) with an active material (3), a pressing step for performing press working on the core substrate to form a plurality of rail shaped protrusions (8), an active material removal step for removing the active material to form core substrate exposed sections (13) by applying ultrasonic vibrations to the rail shaped protrusions, a flattening step for compressing the core substrate exposed sections down to an identical level with the other sections, and a cutting step for cutting predetermined sections including the core substrate exposed sections.Type: GrantFiled: August 29, 2001Date of Patent: April 12, 2005Assignee: Matsushita Electric Industrial Co., Ltd.Inventors: Masaharu Miyahisa, Hideyuki Kumakiri, Takehiko Matsunaga, Koichi Kojima
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Patent number: 6849361Abstract: A manufacturing method for a sintered substrate of alkaline batteries is provided. The manufacturing method includes a first step for mixing particles with a pore former and applying the mixture to a porous substrate, and a second step for sintering the porous substrate and the applied mixture. The particles are made of nickel or principally made of nickel, and the surfaces of the pore former particles each have a coating made of nickel or principally made of nickel. The pore former can be made from resin or any other materials if it disappears when sintered. The pore former particles should preferably have a spheric shape, but is does not matter whether the pore former particles are solid or hollow. Using such sintered substrate for an electrode, an alkaline storage battery can exhibit a high performance.Type: GrantFiled: January 25, 2002Date of Patent: February 1, 2005Assignee: Sanyo Electric Co., Ltd.Inventors: Hiroshi Fukuda, Masao Takee, Hideo Kasuga
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Patent number: 6824925Abstract: A base for an electrode plate that has an excellent ability to retain an active material and can be manufactured at a low cost, a method for manufacturing the same, and an alkaline storage battery using the same are provided. The method includes (i) forming a slurry containing water, a powder containing nickel, and a hollow particle formed of an organic compound, (ii) applying the slurry to a support made of metal, thereby forming a sheet, and (iii) burning the sheet, thereby forming a porous layer joined to the support by a metallic bond.Type: GrantFiled: July 10, 2002Date of Patent: November 30, 2004Assignee: Matsushita Electric Industrial Co., Ltd.Inventors: Yoshiyuki Muraoka, Ichiro Takeuchi, Yusuke Ozaki
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Patent number: 6815121Abstract: A matted particulate electrode located between the current collector and a porous separator of a rechargeable lithium battery is described, which contains electro-active particles intermixed with pliable, solid, lithium ion conducting, polymer electrolyte filaments having adhesive surfaces. The electro-active particles and the optionally added electro-conductive carbon particles adhere to the tacky surface of the adhesively interlinking polymer electrolyte filaments. The matted particulate electrode is impregnated with an organic solution containing another lithium compound. In a second embodiment the porous separator is coated on at least one of its faces, with polymer electrolyte having an adhesive surface and made of the same polymer as the electrolyte filaments. The polymer electrolyte filaments in the matted layer may adhere to the coated surface of the separator.Type: GrantFiled: July 17, 2001Date of Patent: November 9, 2004Assignee: Electrovaya Inc.Inventors: Sankar Dasgupta, James K. Jacobs, Rakesh Bhola
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Patent number: 6815120Abstract: A workpiece, in which a lead is laid on top of a three-dimensional porous metal body, is placed between an ultrasonic horn and an anvil with a lead portion facing the ultrasonic horn. A support is raised so that the lead portion of the workpiece is pressed between the ultrasonic horn and the anvil. While being rotated around a central shaft with a motor, the ultrasonic horn vibrates at a frequency of 20 kHz in the shaft direction. Thus, the workpiece is advanced continuously, so that the lead is bonded ultrasonically to the three-dimensional porous metal body (i.e., metal-to-metal bonding is established). It is possible to provide a battery electrode that can be produced continuously at a lower running cost, reduce the faulty welding with a current collecting plate, and prevent short-circuits.Type: GrantFiled: April 9, 2001Date of Patent: November 9, 2004Assignees: Matsushita Electric Industrial Co., Ltd., Toyota Jidosha Kabushiki KaishaInventors: Hiroshi Inoue, Kiwamu Inui, Mitsugu Takaki, Shinichi Hojioka
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Patent number: 6800398Abstract: A battery used by rolling a pole plate, formed by filling an active material, around a substrate using a band-shaped metal porous body having three-dimensionally linked spaces is inferior in flexibility and likely to short-circuit. According to this invention, grooves are formed in active material-filled substrate filled with the above active material, and then the grooved substrate is pressed flat to form groove active material layers, whereby cracks are made in the bottoms of the grooves preferentially, and cracks are pressed by the groove active material layers and blocked to prevent the flow-out of swelled projections of the cracks and the active material. Accordingly, a higher-capacity and higher-reliability battery is provided.Type: GrantFiled: June 13, 2001Date of Patent: October 5, 2004Assignee: Matsushita Electric Industrial Co., Ltd.Inventors: Satoshi Furuya, Gota Asano, Masaharu Miyahisa, Ayahito Shiosaki, Yoshihisa Inaba, Yoshiyuki Tada
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Patent number: 6797432Abstract: A cadmium negative electrode is prepared having excellent cycle characteristics without impairing the production efficiency even in case the impurities incorporated during filling the active material should be removed by heat treatment. The method includes filling the nickel sintered substrate with an active material based on cadmium hydroxide to obtain an active material filled electrode plate; heating the active material filled electrode plate to change at least a part of the thus filled active material based on cadmium hydroxide into cadmium oxide; adding polyvinyl alcohol into the active material; and hydrating the active material filled electrode plate added with polyvinyl alcohol i.e., immersing the electrode plate in an alkaline solution to convert cadmium oxide into cadmium hydroxide.Type: GrantFiled: March 22, 2002Date of Patent: September 28, 2004Assignee: Sanyo Electric Co., Ltd.Inventor: Akihiko Konsha
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Patent number: 6790414Abstract: An oxygen enrichment system is provided. The system includes an electrochemical cell for generating oxygen from ambient air. The electrochemical cell extracts oxygen from ambient air based on hydroxide conduction. A mixer is provided in fluid communication with ambient air, and an outlet provides oxygen enriched air to a user or air-breathing apparatus. In further embodiments, a purification system is also included. The air enrichment system may be employed with suitable batteries to provide a portable air enrichment device.Type: GrantFiled: April 17, 2002Date of Patent: September 14, 2004Assignee: InventQjaya Sdn. Bhd.Inventors: Tsepin Tsai, Sadeg M. Faris
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Patent number: 6772489Abstract: A hydrophilic collector for alkaline secondary batteries is formed of a nonwoven fabric plated with nickel in which the nonwoven fabric is hydrophilized by sulfonation, a gaseous fluorine treatment, or vinyl monomer grafting. A method for making the collector includes a hydrophilizing step of a nonwoven fabric comprising at least one of a polyolefin fiber and a polyamide fiber, and a plating step of applying nickel plating to the hydrophilic nonwoven fabric. Preferably, the nickel plating is electroless plating, and the nonwoven fabric has a plurality of micropores extending from one surface to the other surface thereof. An electroplating film may be deposited on the electroless plated film, if necessary. This collector facilitates assembling a battery which exhibits improved high-rate discharge characteristics due to improved adhesiveness of the plated nickel film to the nonwoven fabric.Type: GrantFiled: November 4, 2002Date of Patent: August 10, 2004Assignees: Mitsubishi Materials Corporation, Japan Vilene Company, Ltd.Inventors: Hiroyuki Imai, Kaori Yoshida, Toshiaki Takase, Kazuya Satou
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Patent number: 6740441Abstract: Provided are low-cost, mechanically strong, highly electronically conductive current collects and associated structures for solid-state electrochemical devices, techniques for forming these structures, and devices incorporating the structures. The invention provides solid state electrochemical devices having as current interconnects a ferritic steel felt or screen coated with a protective oxide film.Type: GrantFiled: December 18, 2002Date of Patent: May 25, 2004Assignee: The Regents of the University of CaliforniaInventors: Craig P. Jacobson, Steven J. Visco, Lutgard C. DeJonghe
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Patent number: 6699620Abstract: A lead alloy coating for a positive grid of a lead acid battery is provided. The lead alloy coating includes a tin content of at least about 0.1%, but not more than about 3%; and a residual lead content. The lead alloy coating optionally includes a calcium content of at least about 0.01%, but not more than about 0.1%, with or without a silver content of at least about 0.01%, but not more than about 0.1%. Alternatively, the lead alloy coating optionally includes a barium content of at least about 0.01%, but not more than about 0.1%, with or without a silver content of at least about 0.01%, but not more than about 0.1%.Type: GrantFiled: July 19, 2001Date of Patent: March 2, 2004Assignee: Delphi Technologies, Inc.Inventors: Lu Zhang, John Lewis Ayres
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Patent number: 6641956Abstract: An electrode plate of a storage battery includes a rectangular, conducting, porous base plate 12 and a paste 13 containing an active substance, spread over the surfaces of the base plate 12, and filled in the hollow spaces in the base plate by rolling so as to form layers attached to the surfaces of the base plate 12. When shaping the base plate 12, the corners C of the base plate 12 are rounded, and the edge of at least one of the sides S of the base plate 11 is rounded in cross section. Thus, burrs at the corners C and along the sides S are removed so that the exertion of excessive contact pressure on the corners C and the sides S of the base plate is prevented in the assembled state of the storage battery, whereby the occurrence of short circuit is also prevented.Type: GrantFiled: August 1, 2000Date of Patent: November 4, 2003Assignees: Honda Giken Kogyo Kabushiki Kaisha, Sanoh Kogyo Kabushiki KaishaInventors: Hiroyuki Suzuki, Kyoichi Ariga, Hiroyuki Takayasu
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Patent number: 6627347Abstract: A rectangular electrode plate including a core metal sheet and a mixture paste coated thereon has a lead on one long side edge thereof where no mixture is coated, and a mixture non-coated part on the other side edge thereof. Positioning holes are punched only in the lead so that the stress exerted when punching the holes will not cause the mixture paste to fall off. Stacked electrode plates are accommodated within a magazine with a certain clearance between the three side edges of the electrodes other than the lead and the inner surface of the magazine, and fed one by one to be assembled into an electrode plate group to form a battery.Type: GrantFiled: April 12, 2001Date of Patent: September 30, 2003Assignees: Matsushita Electric Industrial Co., Ltd., Toyota Jidosah Kabushiki KaishaInventors: Shinsuke Fukuda, Izumi Yamamura, Hiromi Kajiya, Yoshihiro Tokutome
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Patent number: 6623891Abstract: A polymer electrolyte battery having a high discharge capacity, a high mechanical strength, and a high heat resistance is provided. This polymer electrolyte battery includes: a polymer electrolyte layer 51 covering an edge face 20a of a positive electrode plate 20 and an edge part 40b of a porous membrane 40; a polymer electrolyte layer 52 covering an edge face 30a of a negative electrode plate 39 and an edge part 40c of the porous membrane 40; and a polymer electrolyte layer 53 covering an edge face 40a of the porous membrane 40 in a manner that connects the polymer electrolyte layer 51 with the polymer electrolyte layer 52.Type: GrantFiled: March 23, 2001Date of Patent: September 23, 2003Assignee: Sanyo Electric Co., Ltd.Inventor: Mikiya Yamasaki
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Publication number: 20030170544Abstract: Provided are low-cost, mechanically strong, highly electronically conductive current collects and associated structures for solid-state electrochemical devices, techniques for forming these structures, and devices incorporating the structures. The invention provides solid state electrochemical devices having as current interconnects a ferritic steel felt or screen coated with a protective oxide film.Type: ApplicationFiled: December 18, 2002Publication date: September 11, 2003Inventors: Craig P. Jacobson, Steven J. Visco, Lutgard C. DeJonghe
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Patent number: 6617071Abstract: A grid plate for high power lead acid battery having a plate (14) covered with a conductive polymeric matrix (10) of preferably polyaniline and its derivatives, which is then coated with nanoscale particles of active material (14) such as lead sulfate and basic lead sulfate complexes.Type: GrantFiled: May 24, 2001Date of Patent: September 9, 2003Assignee: Delphi Technologies, Inc.Inventors: Rongrong Chen, Wellington Y. Kwok
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Patent number: 6596436Abstract: The present invention provides a sintered nickel positive electrode plates for alkaline storage batteries with a high capacity density in which the working voltage during discharge is kept from dropping and the utilization of the positive electrode active material remains high even at high temperatures. The electrode comprises a porous sintered nickel substrate and metal hydroxides mainly composed of nickel hydroxide impregnated in the substrate, the metal hydroxides including: a first layer comprising a hydroxide of at least one element selected from the group consisting of yttrium, ytterbium and lutetium, and being in contact with the substrate; a second layer comprising a mixture of nickel hydroxide and cobalt hydroxide, and covering the first layer; and a third layer comprising cobalt hydroxide and covering the second layer.Type: GrantFiled: May 3, 2001Date of Patent: July 22, 2003Assignee: Matsushita Electric Industrial Co., LtdInventors: Masayoshi Maruta, Yoshiyuki Muraoka, Masumi Katsumoto, Fumihiko Yoshii
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Publication number: 20030087156Abstract: A multicell assembly for a redox flow electrolyzer is constituted by alternately stacking pre-assembled elements, typically an electrode subassembly including porous mat electrodes on opposite faces of a conductive plate and a permionic membrane subassembly. Pressure drops in circulating the electrolyte solutions through respective cell compartments, in contact with fluid permeable three-dimensional electrodes in the form of porous mats, are reduced while enhancing evenness of electrolyte refreshing over the whole geometrical cell-area, by defining cooperatively interleaved flow channels in the porous mat electrode. Two interleaved orders of parallel flow channels are defined. All the parallel spaced channels of each order extend from a common orthogonal base channel formed along the respective inlet or outlet side of the electrolyte flow chamber, and terminate short of reaching the base channel of the other.Type: ApplicationFiled: December 4, 2002Publication date: May 8, 2003Applicant: SQUIRREL HOLDINGS LTD.Inventors: Barry Michael Broman, Andrea Zocchi
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Patent number: 6548210Abstract: A nickel electrode for alkaline secondary battery including a porous sintered nickel substrate loaded with a nickel hydroxide-based active material, the nickel electrode has a configuration wherein a surface portion of the active material loaded into the sintered nickel substrate is provided with a combination of a first coating layer of a suitable compound and a second coating layer of a suitable compound, or a coating layer of a compound of two or more suitable elements, or wherein the coating layer of two or more suitable elements is formed between the sintered nickel substrate and the active material.Type: GrantFiled: November 29, 1999Date of Patent: April 15, 2003Assignee: Sanyo Electric Co., Ltd.Inventors: Katsuhiko Shinyama, Reizo Maeda, Yasuyuki Harada, Tadayoshi Tanaka, Yoshinori Matsuura, Toshiyuki Nohma, Ikuo Yonezu
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Patent number: 6541159Abstract: A solid-state hydroxide (OH−) conductive membrane provides up to five times higher ionic conductivity and surface oxygen exchange rate than conventional MIEC membranes, while operating at significantly lower temperatures and providing reduced overall system cost. The hydroxide conductive membrane utilizes a porous ceramic backbone, pores of which are injected with an electrolyte. A catalyst is provided as discrete layers disposed at the anode and cathode. The membrane of the present invention may be utilized in combination with an external voltage source to drive the oxygen generating reaction. Alternatively, the pores may be metallized and a pressure gradient utilized to drive the reaction. The membrane thus provides discrete materials to provide ionic conduction, electronic conduction, and structural support.Type: GrantFiled: August 12, 1999Date of Patent: April 1, 2003Assignee: Reveo, Inc.Inventors: Lin-Feng Li, Wayne Yao, Muguo Chen
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Patent number: 6479188Abstract: A seamless cathode tube is made by applying a cathode coating mixture to a current collector tube. After application, the cathode coating mixture stiffens to form a seamless cathode tube.Type: GrantFiled: October 13, 1999Date of Patent: November 12, 2002Assignee: The Gillette CompanyInventors: Ignacio Chi, George Cintra, Gary Searle
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Publication number: 20020150821Abstract: A manufacturing method for a sintered substrate of alkaline batteries is provided. The manufacturing method includes a first step for mixing particles with a pore former and applying the mixture to a porous substrate, and a second step for sintering the porous substrate and the applied mixture. The particles are made of nickel or principally made of nickel, and the surfaces of the pore former particles each have a coating made of nickel or principally made of nickel. The pore former can be made from resin or any other materials if it disappears when sintered. The pore former particles should preferably have a spheric shape, but is does not matter whether the pore former particles are solid or hollow. Using such sintered substrate for an electrode, an alkaline storage battery can exhibit a high performance.Type: ApplicationFiled: January 25, 2002Publication date: October 17, 2002Applicant: Sanyo Electric Co., Ltd.Inventors: Hiroshi Fukuda, Masao Takee, Hideo Kasuga
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Patent number: 6465133Abstract: A metallic porous body comprises a metallic framework having a three-dimensional network with a continuous-pore structure formed by linking sub-stantially polyhedral cells. The substantially polyhedral cells have an average cell diameter of about 200 to about 300 &mgr;m and an average window diameter of about 100 to about 200 &mgr;m. The metallic porous body can be obtained by the following method, for instance: First, a plastic porous body is provided that has an average cell diameter of about 200 to about 300 &mgr;m and an average window diameter of about 100 to about 200 &mgr;m. Second, a conductive layer is formed on a surface of the framework of the plastic porous body to produce a conductive porous body having a resistivity of about 1 k&OHgr;·cm or less. Finally, a continuous metal-plated layer is formed on a surface of the conductive layer by electroplating, with the conductive porous body serving as the cathode.Type: GrantFiled: May 9, 2000Date of Patent: October 15, 2002Assignee: Sumitomo Electric Industries, Ltd.Inventors: Ayao Kariya, Noriki Hayashi, Shinji Inazawa, Masatoshi Majima
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Patent number: 6465125Abstract: This invention provides a nonaqueous electrolyte secondary battery including an electrode group comprising a positive electrode, a negative electrode, and a separator for separating the positive and negative electrodes from each other, a jacket for housing the electrode group, and a nonaqueous electrolyte with which the electrode group is impregnated. The separator contains a porous sheet whose air permeability is 600 sec/100 cm3 or less. The positive electrode and the separator are adhered to each other by adhesive polymers that are held in voids of the positive electrode and those of the separator, and the negative electrode and the separator are adhered to each other by adhesive polymers that are held in voids of the negative electrode and those of the separator.Type: GrantFiled: September 16, 1999Date of Patent: October 15, 2002Assignee: Kabushiki Kaisha ToshibaInventors: Norio Takami, Hiroyuki Hasebe, Takahisa Osaki, Motoya Kanda
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Patent number: 6455196Abstract: The present invention provides alkaline storage batteries high in energy density and excellent in overdischarge resistance, and, besides, less in decrease of capacity even if charging and discharging cycle is repeated at high temperatures. There is used a positive electrode comprising a foamed nickel substrate having the number of pores of 80-160 pores/inch (PPI2D) and a thickness of skeleton of 30-60 &mgr;m in which spherical nickel hydroxide solid solution particles having an average particle size of 5-20 &mgr;m and a cobalt oxide conductive agent having an average particle size of 1 &mgr;m or less and mainly composed of &ggr;-cobalt oxyhydroxide having a cobalt valence of higher than 3.0 are held and the total occupying ratio of the spherical nickel hydroxide solid solution particles and the cobalt oxide conductive agent based on the whole electrode plate is in the range of 75-85 vol %.Type: GrantFiled: December 11, 1998Date of Patent: September 24, 2002Assignee: Matsushita Electric Industrial Co., Ltd.Inventors: Fumio Kato, Tatsuhiko Suzuki, Futoshi Tanigawa, Yoshitaka Dansui, Kohji Yuasa
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Patent number: 6451485Abstract: The performance of electrochemical energy devices such as batteries, fuel cells, capacitors and sensors is enhanced by the use of electrically conducting ceramic materials in the form of fibers, powder, chips and substrates.Type: GrantFiled: June 12, 1998Date of Patent: September 17, 2002Assignee: Advanced Power Devices, Inc.Inventors: David James, Daniel B. Allison, II, John J. Kelley, James B. Doe
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Patent number: 6447957Abstract: A collector for a secondary battery includes a metal foil having throughholes shaped or arranged to achieve an increased hole area ratio to improve an active material's adhesion thereto. A throughhole in the metal foil has a largest dimension of at least 1.55 mm, and the foil has a hole area ratio of at least 40%, and a thickness of at least 5 &mgr;m and at most 200 &mgr;m. The throughhole has a peripheral shape including two substantially straight sides that extend along lines intersecting with each other on their respective extensions to form an acute angle at a corner of the throughhole. To form the metal foil, a resist film with a predetermined pattern is arranged on a solid foil, and is used as a mask to etch the foil to provide the plurality of throughholes penetrating the foil.Type: GrantFiled: April 5, 2000Date of Patent: September 10, 2002Assignee: Toyo Aluminum Kabushiki KaishaInventors: Hiroyuki Sakamoto, Hiroshi Tada, Toshihisa Tamai
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Publication number: 20020106561Abstract: A positive electrode for a lithium-sulfur battery that includes a sulfur-based positive active material, a conductive agent and a binder filled in a porous current collector. The lithium-sulfur battery having the positive electrode can improve capacity characteristics by enhancing the utilization of the sulfur-based positive active material, and also improve cycle life characteristics by inhibiting the detachment of the active material from the current collector.Type: ApplicationFiled: November 13, 2001Publication date: August 8, 2002Applicant: SAMSUNG SDI CO., LTD.Inventors: Jaewoan Lee, Yunsuk Choi, Yongju Jung, Soo Seok Choi, Duck Chul Hwang, Joo Soak Kim
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Patent number: 6379845Abstract: A conductive porous body that has a conductive layer almost free from impurities and that enables a metallic porous body having extremely low resistance to be produced with high productivity and production efficiency, and a metallic porous body and a battery plate both produced by using the conductive porous body. The conductive porous body has a nickel conductive layer formed on the surface of the framework of a plastic porous body having a continuous-pore structure. The conductive layer is formed by the deposition of nickel from an aqueous solution containing nickel compounds with the use of a reducing agent containing titanium compounds. The metallic porous body can be obtained by forming a continuous metal-plated layer on the surface of the framework of the conductive porous body. The metal-plated layer is formed by electroplating with the conductive porous body serving as the cathode. The battery plate consists mainly of the metallic porous body.Type: GrantFiled: April 3, 2000Date of Patent: April 30, 2002Assignee: Sumitomo Electric Industries, Ltd.Inventors: Shinji Inazawa, Masatoshi Majima, Ayao Kariya
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Patent number: 6358650Abstract: A primed current collector for use in an electrochemical cell comprising a current collector having a first surface and a second surface, and a primer applied to at least a portion of the first and/or second surfaces of the current collector, wherein the primer comprises a uniform layer of lithium polysilicate.Type: GrantFiled: July 28, 1999Date of Patent: March 19, 2002Assignee: Mitsubishi Chemical CorporationInventors: Michael McLin, Denis G. Fauteux
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Patent number: 6337160Abstract: The invention relates to novel manganese dioxide electrodes comprising modified, electrochemically active manganese dioxide, to a method for fabricating these novel manganese dioxide electrodes and to the use of these in rechargeable cells.Type: GrantFiled: October 5, 1999Date of Patent: January 8, 2002Assignee: Merck Patent Gesellschaft mit beschrankterInventors: Volker Hilarius, Gerhard Pfaff, Ralf Glausch, Dietmar Rahner, Waldfried Plieth, Matthias Kloss
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Publication number: 20010031402Abstract: A hydrophilic collector for alkaline secondary batteries is formed of a nonwoven fabric plated with nickel in which the nonwoven fabric is hydrophilized by sulfonation, a gaseous fluorine treatment, or vinyl monomer grafting. A method for making the collector includes a hydrophilizing step of a nonwoven fabric comprising at least one of a polyolefin fiber and a polyamide fiber, and a plating step of applying nickel plating to the hydrophilic nonwoven fabric. Preferably, the nickel plating is electroless plating, and the nonwoven fabric has a plurality of micropores extending from one surface to the other surface thereof. An electroplating film may be deposited on the electroless plated film, if necessary. This collector facilitates assembling a battery which exhibits improved high-rate discharge characteristics due to improved adhesiveness of the plated nickel film to the nonwoven fabric.Type: ApplicationFiled: February 21, 2001Publication date: October 18, 2001Applicant: Mitsubishi Materials CorporationInventors: Hiroyuki Imai, Kaori Yoshida, Toshiaki Takase, Kazuya Satou
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Patent number: 6280878Abstract: An electrode comprising a porous metal member in sheet form having a three-dimensional skeleton structure and a solid polymer electrolyte is used to construct a lithium secondary battery and an electric double-layer capacitor. Owing to the increased retaining force of the gel electrolyte component to a current collector, the gel electrolyte component can be directly applied to the current collector, contributing to mass scale productivity and cost reduction.Type: GrantFiled: May 29, 1998Date of Patent: August 28, 2001Assignee: TDK CorporationInventors: Satoshi Maruyama, Masato Kurihara, Akira Kakinuma