Expanded Metal Patents (Class 429/242)
  • Patent number: 11532824
    Abstract: Energy storage devices, battery cells, and batteries of the present technology may include a first cell and a second cell disposed adjacent the first cell. The devices may include a stacked current collector coupled between the first cell and the second cell. The current collector may include a grid or matrix, and may include a combination of conductive and insulative materials.
    Type: Grant
    Filed: February 12, 2019
    Date of Patent: December 20, 2022
    Assignee: Apple Inc.
    Inventors: Andrew C. Chu, Christopher T. Campbell, Qingcheng Zeng, Kenzo Nagai, Isaac S. Harper, Donald G. Dafoe
  • Patent number: 11123785
    Abstract: In this part that includes a cut end surface consisting of a surface-treated steel sheet that has been cut, the shape of the cut end surface is such that the length of a first shear droop occurring in the sheet thickness direction is at least 0.10 times the sheet thickness of the surface-treated steel sheet, and the length of a second sheer droop occurring in the planar direction is at least 0.45 times the sheet thickness of the surface-treated steel sheet. Furthermore, in the cutting process a die is used for which the clearance between the punch and the die is 1-20% of the plate thickness of the surface-treated steel plate, and the shoulder portion of the die and/or the punch is provided with a radius of curvature of at least 0.12 times the plate thickness of the surface-treated steel plate.
    Type: Grant
    Filed: June 25, 2019
    Date of Patent: September 21, 2021
    Assignee: NIPPON STEEL CORPORATION
    Inventors: Hirokazu Sasaki, Naofumi Nakamura, Yudai Yamamoto
  • Patent number: 10541420
    Abstract: Battery electrodes are provided that can include a conductive core supported by a polymeric frame. Methods for manufacturing battery electrodes are provided that can include: providing a sheet of conductive material; and framing the sheet of conductive material with a polymeric material. Batteries are provided that can include a plurality of electrodes, with individual ones of the electrodes comprising a conductive core supported by a polymeric frame.
    Type: Grant
    Filed: December 12, 2017
    Date of Patent: January 21, 2020
    Assignee: COPPERWATTS LLC
    Inventors: Alfred T. Volberding, Bradley W. Stone
  • Patent number: 10276873
    Abstract: Provided are a current collector for a battery, including: a base material; adhesive layers positioned on the base material; and metal mesh layers positioned on the adhesive layers, in which the metal mesh layer includes a plurality of metal mesh patterns, and holes positioned between the metal mesh patterns, and a method of manufacturing the same. An active material is applied onto the metal mesh layer through the holes of the metal mesh layer, and thus a contact area of the metal mesh layer and the active material is increased, so that it is possible to restrict the active material from being deintercalated from the current collector and improve a cycle lifespan property of a battery.
    Type: Grant
    Filed: April 22, 2013
    Date of Patent: April 30, 2019
    Assignee: KOREA INSTITUTE OF MACHINERY & MATERIALS
    Inventors: Man Kim, Joo Yul Lee, Sang Yeoul Lee, Yong Soo Jeong, Do Yon Chang, Kyu Hwan Lee, Cheol Nam Yang, Chang Rae Lee, Seong Bong Yim, Dong Chan Lim, Jae Hong Lim, Young Sup Song, Sung Mo Moon, Su Sub Cha
  • Patent number: 9899684
    Abstract: Battery electrodes are provided that can include a conductive core supported by a polymeric frame. Methods for manufacturing battery electrodes are provided that can include: providing a sheet of conductive material; and framing the sheet of conductive material with a polymeric material. Batteries are provided that can include a plurality of electrodes, with individual ones of the electrodes comprising a conductive core supported by a polymeric frame.
    Type: Grant
    Filed: February 27, 2017
    Date of Patent: February 20, 2018
    Assignee: COPPERWATTS LLC
    Inventors: Alfred T. Volberding, Bradley W. Stone
  • Patent number: 9685647
    Abstract: A separator includes a polyolefin base film and a coating layer, the coating layer containing inorganic particles having an average particle size of about 1 nm to about 700 nm and an organic binder of a polyvinylidene fluoride homopolymer, the coating layer having a density of about 1.2 g/cm3 to about 2 g/cm3, the coating layer being disposed on one or both sides of the base film.
    Type: Grant
    Filed: February 27, 2013
    Date of Patent: June 20, 2017
    Assignee: CHEIL INDUSTRIES, INC.
    Inventors: Ki Chul Hong, Jae Goo Doh, Geon Ja Lim, Jun Ho Chung
  • Patent number: 9634311
    Abstract: A separator includes a coating layer, the coating layer containing a polyvinylidene fluoride homopolymer, a polyvinylidene fluoride-hexafluoropropylene copolymer, a solvent, and inorganic particles, the solvent being present in an amount of about 100 ppm or less in the coating layer.
    Type: Grant
    Filed: February 27, 2013
    Date of Patent: April 25, 2017
    Assignee: Cheil Industries, Inc.
    Inventors: Ki Chul Hong, Myung Kook Park, Jin Kyu Park, Jun Ho Chung
  • Patent number: 9583758
    Abstract: Battery electrodes are provided that can include a conductive core supported by a polymeric frame. Methods for manufacturing battery electrodes are provided that can include: providing a sheet of conductive material; and framing the sheet of conductive material with a polymeric material. Batteries are provided that can include a plurality of electrodes, with individual ones of the electrodes comprising a conductive core supported by a polymeric frame.
    Type: Grant
    Filed: June 18, 2015
    Date of Patent: February 28, 2017
    Assignee: COPPERWATTS LLC
    Inventors: Alfred T. Volberding, Bradley W. Stone
  • Patent number: 9548497
    Abstract: A current collector including: a polymer film including a first major surface, an opposite second major surface, and a plurality of openings extending through a thickness of the polymer film; a first layer on the first major surface of the polymer film; a second layer on the second major surface of the polymer film; and a third layer on an inner surface of an opening of the plurality of openings, wherein the third layer contacts the first layer and the second layer, and wherein the first layer, the second layer, and the third layer each independently has an electrical conductivity of greater than 10 Siemens per meter.
    Type: Grant
    Filed: June 10, 2011
    Date of Patent: January 17, 2017
    Assignee: EaglePicher Technologies, LLC
    Inventors: Boris Ravdel, Frank Puglia
  • Patent number: 9299980
    Abstract: Battery electrodes are provided that can include a conductive core supported by a polymeric frame. Methods for manufacturing battery electrodes are provided that can include: providing a sheet of conductive material; and framing the sheet of conductive material with a polymeric material. Batteries are provided that can include a plurality of electrodes, with individual ones of the electrodes comprising a conductive core supported by a polymeric frame.
    Type: Grant
    Filed: March 11, 2013
    Date of Patent: March 29, 2016
    Assignee: COPPERWATTS LLC
    Inventors: Alfred T. Volberding, Bradley W. Stone
  • Patent number: 9160026
    Abstract: An MEA 15 is arranged between frames 13, 14. A first gas flow passage forming member 21 is arranged between an anode electrode layer 17 of the MEA 15 and a first separator 23 fixed to an upper surface of the frame 13. A second gas flow passage forming member 22 is arranged between a cathode electrode layer 18 of the MEA 15 and a second separator 24 fixed to a lower surface of the frame 14. The gas flow passage forming members 21, 22 are each formed by a metal lath 25. The metal lath is formed by forming a plurality of through holes 26 in a thin metal plate in a mesh-like manner and forming the thin metal plate in a stepped shape. The gas flow passage forming members 21, 22 each include a plurality of annular portions 27 forming the through holes 26. Each of the annular portions 27 has a flat surface portion 28a in a first contact portion 28, which contacts a carbon paper 19, 20.
    Type: Grant
    Filed: June 16, 2009
    Date of Patent: October 13, 2015
    Assignees: Toyota Shatai Kabushiki Kaisha, Toyota Jidosha Kabushiki Kaisha
    Inventors: Satoshi Futami, Keiji Hashimoto, Tomokazu Hayashi
  • Patent number: 8883345
    Abstract: Provided is a prismatic battery comprising stacked positive electrode plates, negative electrode plates and separator layers therebetween. The positive and negative electrode plates extend beyond a periphery of the electrode stack. The positive electrode plates are fused to form a positive current collector, and the negative electrode plates are fused to form a negative current collector. Both the positive and negative electrode plates comprise a metal foam and are compressed between about 42 and 45% of the original thickness.
    Type: Grant
    Filed: December 23, 2008
    Date of Patent: November 11, 2014
    Assignee: Encell Technology LLC
    Inventor: Randy Ogg
  • Patent number: 8883346
    Abstract: Provided is a method of manufacturing a prismatic battery, or a series of prismatic batteries. The method comprises stacking positive electrode plates, negative electrode plates and separator layers therebetween. The positive and negative electrode plates extend beyond a periphery of the electrode stack. The positive electrode plates are fused to form a positive current collector, and the negative electrode plates are fused to form a negative current collector.
    Type: Grant
    Filed: March 14, 2013
    Date of Patent: November 11, 2014
    Assignee: Encell Technology
    Inventor: Randy Gene Ogg
  • Patent number: 8741487
    Abstract: A current collector comprising a frame conductor formed as a closed undulating perimeter, and a conductive mesh formed within the frame conductor is described. The conductive mesh is comprised of a plurality of radial struts, each radial strut having a central end and an outer end. The radial struts emanate from a junction within the undulating perimeter with their outer ends connected to the undulating perimeter of the frame. The conductive mesh may include branch struts having proximal ends and distal ends, with the proximal ends connected to the radial struts. The distal ends of the branch struts may be connected to the undulating perimeter, or to adjacent radial struts. The current collector is used in an electrochemical cell, wherein a first electrode active material is contacted to at least one of first and second major sides of the current collector to provide a first electrode.
    Type: Grant
    Filed: August 28, 2009
    Date of Patent: June 3, 2014
    Assignee: Greatbatch Ltd.
    Inventors: John C. Duggan, Michael R. Blendowski, Donald F. Kaiser, Ashish Shah
  • Publication number: 20130330614
    Abstract: In an electrode according to the present invention including a three-dimensional network aluminum porous body as a base material, the electrode is a sheet-shaped electrode, and a cell of the three-dimensional network aluminum porous body has an elliptic shape having a minor axis in the thickness direction of the electrode in a cross section parallel to the longitudinal direction and thickness direction of the electrode, and a cell of the three-dimensional network aluminum porous body has an elliptic shape having a minor axis in the thickness direction of the electrode in a cross section parallel to the width direction and thickness direction of the electrode. The electrode is preferably obtained by subjecting the three-dimensional network aluminum porous body to at least a current collecting lead welding step, an active material filling step and a compressing step.
    Type: Application
    Filed: August 19, 2013
    Publication date: December 12, 2013
    Applicants: SUMITOMO ELECTRIC TOYAMA CO., LTD., SUMITOMO ELECTRIC INDUSTRIES, LTD.
    Inventors: Akihisa HOSOE, Kazuki OKUNO, Hajime OTA, Koutarou KIMURA, Kengo GOTO, Hideaki SAKAIDA, Junichi NISHIMURA
  • Publication number: 20130309579
    Abstract: The invention includes battery electrode core plates utilizing an expanded foil processed to reduce protrusions on the strands of the expanded foil. Expanded foils may be metal or metal-coated plastic. Reducing or eliminating protrusions on the expanded foil mitigate the risk of internal shorts due to protrusion cross-over or “hot spots.” Protrusion reduction may be achieved using chemical etching via various chemical or electrochemical processes that preferentially free or remove material from burrs and free chads, in addition to removing material from sharp edges of the expanded foil.
    Type: Application
    Filed: May 16, 2012
    Publication date: November 21, 2013
    Applicant: DEXMET CORPORATION
    Inventors: Harry Shimp, Robert Bochman, Kenneth Mull
  • Publication number: 20130252103
    Abstract: Electrodes comprising metal support structures and methods for making the same are generally described. In certain embodiments, the electrodes described herein comprise a metal porous support structure, and an electrode active material at least partially contained within the pores of the porous support structure. In some embodiments, the electrical conductivity of the porous support structure material can ensure that electrons are efficiently transferred through and/or out of the electrode (e.g., to a current collector and/or to an external circuit). The pores within the porous support structure can ensure, in certain embodiments, that the electrode active material is accessible to the electrolyte, thereby enhancing performance of the electrochemical cell in which the electrode is used.
    Type: Application
    Filed: March 8, 2013
    Publication date: September 26, 2013
    Applicant: Sion Power Corporation
    Inventor: Yuriy V. Mikhaylik
  • Patent number: 8465875
    Abstract: It is an object of the present invention to provide a sheet-shaped three-dimensional network aluminum porous body for a current collector which is suitably used for electrodes for nonaqueous electrolyte batteries and electrodes for capacitors, an electrode and a capacitor each using the same. In such a three-dimensional network aluminum porous body for a current collector, the aluminum porous body has been made to have a compressive strength in a thickness direction of 0.2 MPa or more in order to efficiently fill an active material into the sheet-shaped three-dimensional network aluminum porous body.
    Type: Grant
    Filed: May 30, 2012
    Date of Patent: June 18, 2013
    Assignees: Sumitomo Electric Industries, Ltd., Sumitomo Electric Toyama Co., Ltd.
    Inventors: Akihisa Hosoe, Kazuki Okuno, Hajime Ota, Koutarou Kimura, Kengo Goto, Hideaki Sakaida, Junichi Nishimura
  • Publication number: 20130130091
    Abstract: An electricity supply element and the ceramic separator thereof are provided. The ceramic separator is adapted to separate two electrode layers of the electricity supply element for permitting ion migration and electrical separation. The ceramic separator is made of ceramic particulates and the adhesive. The adhesive employs dual binder system, which includes linear polymer and cross-linking polymer. The adhesion and heat tolerance are enhanced by the characteristic of the two type of polymers. The respective position of the two electrode layers are maintained during high operation temperature to improve the stability, and battery performance. Also, the ceramic separator enhances the ion conductivity and reduces the possibility of the micro-short to increase practical utilization.
    Type: Application
    Filed: January 12, 2013
    Publication date: May 23, 2013
    Inventor: Prologium Holding Inc.
  • Publication number: 20130130124
    Abstract: A main object is to produce a porous metal body that can be used as a battery electrode, in particular, that can be used as a negative electrode of a molten-salt battery using sodium. The porous metal body includes a hollow metal skeleton composed of a metal layer containing nickel or copper as a main component, and an aluminum covering layer that covers at least an outer surface of the metal skeleton. The porous metal body further includes a tin covering layer that covers the aluminum covering layer, and is used as a battery electrode. Preferably, the porous metal body has continuous pores due to a three-dimensional network structure thereof, and has a porosity of 90% or more.
    Type: Application
    Filed: July 25, 2011
    Publication date: May 23, 2013
    Applicant: SUMITOMO ELECTRIC INDUSTRIES, LTD.
    Inventors: Atsushi Fukunaga, Shinji Inazawa, Masatoshi Majima, Atsushi Yamaguchi, Koji Nitta, Shoichiro Sakai
  • Publication number: 20130122375
    Abstract: The invention offers a porous metal body that has a three-dimensional network structure, that has less reduction in performance during the pressing and compressing steps when an electrode material is produced, and that can be used as an electrode material capable of achieving good electric properties, a method of producing the porous metal body, and an electrode material and a battery both incorporating the foregoing porous metal body. A porous metal body has a skeleton structure that is formed of a metal layer, that has a three-dimensional network structure, and that has an end portion provided with a nearly spherical portion. It is desirable that the metal be aluminum and that the nearly spherical portion have a diameter larger than the outer diameter of the skeleton structure.
    Type: Application
    Filed: October 10, 2012
    Publication date: May 16, 2013
    Applicant: SUMITOMO ELECTRIC INDUSTRIES, LTD.
    Inventor: SUMITOMO ELECTRIC INDUSTRIES, LTD.
  • Publication number: 20130040205
    Abstract: The method for producing an electrode for an electrochemical element of the present invention includes a slurry filling step of filling a slurry containing an active material into continuous pores of an aluminum porous body having the continuous pores, and a slurry drying step of drying the slurry filled, and in this method, after the slurry drying step, an electrode for an electrochemical element is produced without undergoing a compressing step of compressing the aluminum porous body having the slurry filled therein and dried. In the electrode, a mixture containing an active material is filled into continuous pores of an aluminum porous body having the continuous pores, and porosity (%) of the aluminum porous body, the porosity being represented by the following equation, is 15 to 55%.
    Type: Application
    Filed: August 8, 2012
    Publication date: February 14, 2013
    Applicants: SUMITOMO ELECTRIC TOYAMA CO., LTD., SUMITOMO ELECTRIC INDUSTRIES, LTD.
    Inventors: Akihisa HOSOE, Kazuki OKUNO, Hajime OTA, Koutarou KIMURA, Kengo GOTO, Junichi NISHIMURA, Hideaki SAKAIDA
  • Patent number: 8372255
    Abstract: The invention relates to a current collector for electrochemical diaphragm or membrane-type cells, comprising a layer obtained by interlacing or weaving of a multiplicity of first sets of metal wires with a multiplicity of single metal wires or of second sets of metal wires and provided with substantially parallel corrugations. Such layer is coupled to a planar element consisting of a cloth or a flattened stocking formed by weaving of a single metal wire. The current collector is characterised by a low angular coefficient of the pressure/thickness ratio over a wide range of compression levels.
    Type: Grant
    Filed: July 8, 2008
    Date of Patent: February 12, 2013
    Assignee: Uhdenora S.p.A.
    Inventors: Michele Perego, Leonello Carrettin, Dario Oldani, Angelo Ottaviani
  • Patent number: 8334009
    Abstract: An electrode producing method by an electrode producing apparatus has an inclining step of pressing a surface of a current collector sheet with projections extending outwardly from the surface, which is conveyed in a definite direction, to incline the projections in a direction opposite to the definite direction of the current collector sheet; and an applying step of applying a coating solution onto the current collector sheet, the projections of which have been inclined in the inclining step and which is conveyed in the definite direction, by a slit die. After the surface of the current collector sheet is pressed to incline the projections on the sheet surface in the opposite direction to the conveyance direction, the coating solution is applied onto the surface. Therefore, the coating solution can be uniformly applied onto the current collector sheet.
    Type: Grant
    Filed: September 16, 2009
    Date of Patent: December 18, 2012
    Assignee: TDK Corporation
    Inventors: Kazutoshi Emoto, Katsuo Naoi, Kiyonori Hinoki, Masahiro Saegusa, Masayoshi Hirano
  • Patent number: 8256074
    Abstract: A grid for a battery plate is made by forming a metal sheet is formed into a grid-like shape. Rupture due to torsion or stress concentration does not occur in a basal portion of a wire which is drawn out from a node of the grid, thereby preventing corrosion due to electrolyte from advancing so as not to cause a crack of corrosion in an early stage. The invention provides also a battery using the grid for a battery plate, a method of producing the grid for a battery plate, and a battery using it.
    Type: Grant
    Filed: September 29, 2010
    Date of Patent: September 4, 2012
    Assignee: GS Yuasa International Ltd.
    Inventors: Yoshiomi Fujiwara, Ken Sawai
  • Patent number: 8256075
    Abstract: A grid for a battery plate is made by forming a metal sheet is formed into a grid-like shape. Rupture due to torsion or stress concentration does not occur in a basal portion of a wire which is drawn out from a node of the grid, thereby preventing corrosion due to electrolyte from advancing so as not to cause a crack of corrosion in an early stage. The invention provides also a battery using the grid for a battery plate, a method of producing the grid for a battery plate, and a battery using it.
    Type: Grant
    Filed: September 29, 2010
    Date of Patent: September 4, 2012
    Assignee: GS Yuasa International Ltd.
    Inventors: Yoshiomi Fujiwara, Ken Sawai
  • Patent number: 8142935
    Abstract: A method where two disk cutter rolls are used to form slits in a staggered pattern in a metal sheet; disk cutters are part of the disk cutter rolls; ridges are arranged in a peripheral edge of the disk cutters; and valleys are arranged between the ridges, where an axis-to-axis distance L (mm) of the rolls satisfies a relationship of 2r?0.3?L<2r when a radius of a reference circumferential face made with the valleys is r (mm). The method can include a carrying procedure for passing the sheet between the rolls, then carrying the sheet along a peripheral face of one of the rolls, and then pulling out the sheet from the peripheral face.
    Type: Grant
    Filed: August 27, 2008
    Date of Patent: March 27, 2012
    Assignee: GS Yuasa International Ltd.
    Inventors: Yoshiomi Fujiwara, Hiroyuki Tanaka, Tadashi Nishida
  • Patent number: 8088516
    Abstract: A battery cell has a plurality of first and second electrodes of opposite polarities that are interleaved. Each of the first and second electrodes is a sheet of non-woven fabric having a first edge from which a tab projects, and a second edge transverse to and substantially longer than the first edge. The non-woven fabric is coated with a metal in a manner that forms a strip along the second edge which has a greater electrical conductivity than areas more remote from the second edge. The strip extends along the tab. A first terminal is electrically connected to the strip along the tabs of the first electrodes, and a second terminal is electrically connected to the strip along the tabs of the second electrodes.
    Type: Grant
    Filed: November 18, 2005
    Date of Patent: January 3, 2012
    Assignee: Acme Aerospace, Inc.
    Inventors: Christopher A. Baker, John E. Gleason, Anthony Maurizo
  • Patent number: 8048572
    Abstract: A lead acid electric storage battery uses conventional lead-acid secondary battery chemistry. The battery may be a sealed battery, an unsealed battery or a conventional multi-cellbattery. It has 12 to 25 cells in a single case. The case is less than 12 inches long and may be less than 6 inches long. The battery has a set of positive battery grids (plates) which are constructed with a core of thin titanium expanded metal having a thickness preferably, for start batteries etc. in the range 0.1 mm to 0.7 mm and most preferably 0.2 mm to 0.4 mm. The grid cores are of a titanium alloy containing a platinum group metal. The cores are coated with hot melt dip lead and are not lead electroplated. The grid cores expand and contract, with temperature changes, much less than conventional lead grids.
    Type: Grant
    Filed: May 3, 2010
    Date of Patent: November 1, 2011
    Inventor: Eliot Samuel Gerber
  • Patent number: 8039153
    Abstract: A storage battery is provided in which an expand grid is improved with respect to the widths of grid wires 1b, the sectional areas of nodes 1e, and the shapes of meshes 1c, whereby the productivity of the expand grid can be enhanced and the life performance can be improved. As means for attaining the object, a storage battery in which an expand grid is used as a battery plate, the expand grid being a grid member which is formed by expanding a side portion of a collector frame portion 1a of a metal sheet 1 to connect a large number of grid wires 1b to one another in a net-like shape, is configured so that widths of grid wires 1b of a row which is directly connected to the collector frame portion 1a of the expand grid, and a lateral end row are larger than widths of grid wires 1b of at least one of intermediate rows.
    Type: Grant
    Filed: November 23, 2010
    Date of Patent: October 18, 2011
    Assignee: GS Yhasa International, Ltd.
    Inventors: Yoshiomi Fujiwara, Hiroyuki Tanaka
  • Patent number: 7976588
    Abstract: A storage battery is provided in which an expand grid is improved with respect to the widths of grid wires 1b, the sectional areas of nodes 1e, and the shapes of meshes 1c, whereby the productivity of the expand grid can be enhanced and the life performance can be improved. As means for attaining the object, a storage battery in which an expand grid is used as a battery plate, the expand grid being a grid member which is formed by expanding a side portion of a collector frame portion 1a of a metal sheet 1 to connect a large number of grid wires 1b to one another in a net-like shape, is configured so that widths of grid wires 1b of a row which is directly connected to the collector frame portion 1a of the expand grid, and a lateral end row are larger than widths of grid wires 1b of at least one of intermediate rows.
    Type: Grant
    Filed: June 1, 2006
    Date of Patent: July 12, 2011
    Assignee: GS Yussa International Ltd.
    Inventors: Yoshiomi Fujiwara, Hiroyuki Tanaka
  • Publication number: 20110070502
    Abstract: A storage battery is provided in which an expand grid is improved with respect to the widths of grid wires 1b, the sectional areas of nodes 1e, and the shapes of meshes 1c, whereby the productivity of the expand grid can be enhanced and the life performance can be improved. As means for attaining the object, a storage battery in which an expand grid is used as a battery plate, the expand grid being a grid member which is formed by expanding a side portion of a collector frame portion 1a of a metal sheet 1 to connect a large number of grid wires 1b to one another in a net-like shape, is configured so that widths of grid wires 1b of a row which is directly connected to the collector frame portion 1a of the expand grid, and a lateral end row are larger than widths of grid wires 1b of at least one of intermediate rows.
    Type: Application
    Filed: November 23, 2010
    Publication date: March 24, 2011
    Applicant: GS Yuasa Corporation
    Inventors: Yoshiomi FUJIWARA, Hiroyuki TANAKA
  • Patent number: 7814628
    Abstract: A grid for a battery plate is made by forming a metal sheet is formed into a grid-like shape. Rupture due to torsion or stress concentration does not occur in a basal portion of a wire which is drawn out from a node of the grid, thereby preventing corrosion due to electrolyte from advancing so as not to cause a crack of corrosion in an early stage. The invention provides also a battery using the grid for a battery plate, a method of producing the grid for a battery plate, and a battery using it.
    Type: Grant
    Filed: January 25, 2008
    Date of Patent: October 19, 2010
    Assignee: GS Yuasa Corporation
    Inventors: Yoshiomi Fujiwara, Ken Sawai
  • Patent number: 7763084
    Abstract: A method of making a plurality of battery plates includes forming a strip including a plurality of battery grids. Each battery grid includes a grid network bordered by a frame element and includes a plurality of spaced apart grid wire elements. Each grid wire element has opposed ends joined to one of a plurality of nodes to define a plurality of open spaces in the grid network. The method also includes deforming at least a portion of a plurality of the grid wire elements such that the deformed grid wire elements have a first transverse cross-section at a point intermediate their opposed ends that differs from a second transverse cross-section taken at least one of their opposed ends. The method also includes applying a lead alloy coating to the strip, applying battery paste to the strip, and cutting the strip to form a plurality of battery plates.
    Type: Grant
    Filed: June 9, 2008
    Date of Patent: July 27, 2010
    Assignee: Johnson Controls Technology Company
    Inventor: Yu-Lin Chen
  • Patent number: 7732098
    Abstract: A lead acid electric storage battery uses conventional lead-acid secondary battery chemistry. The battery may be a sealed battery, an unsealed battery or a conventional multi-cell battery. The battery has a set of positive battery grids (plates) which are constructed with a body portion of thin titanium expanded metal having a thickness preferably in the range 0.1 mm to 0.9 mm and most preferably 0.2 mm to 0.4 mm. Typically the battery would have over 250 grids in a 12 inch long battery case.
    Type: Grant
    Filed: November 17, 2008
    Date of Patent: June 8, 2010
    Inventor: Eliot Gerber
  • Patent number: 7622218
    Abstract: An electrode in sheet form includes a current collector and an electrode mixture layer carried on each side thereof. The electrode is bent in the longitudinal direction thereof, to cause a large number of cracks in at least the electrode mixture layer to be positioned on the inner side of the current collector when wound, such that the cracks extend from the surface of the electrode mixture layer to the current collector in the direction intersecting with the longitudinal direction of the electrode. This bending process includes the steps of: bending the electrode at a curvature that is smaller than that of the winding core at least once; and thereafter bending the electrode at a curvature that is equal to or larger than that of the winding core. For example, this process is performed by arranging rollers such that their diameters decrease gradually and pressing the electrode against these rollers. This invention provides an electrode that does not break when wound to form an electrode assembly.
    Type: Grant
    Filed: April 6, 2006
    Date of Patent: November 24, 2009
    Assignee: Panasonic Corporation
    Inventors: Kozo Watanabe, Masao Fukunaga, Ichiro Yasuoka, Toshiro Kume
  • Patent number: 7488557
    Abstract: The present invention relates to a lead-acid battery Comprising a positive and a negative electrode, each having a current collector comprising an expanded grid, characterized in that at least one of the positive electrode and the negative electrode contains an organic binder in an active material layer at an edge portion thereof. This makes it possible to suppress an internal short circuit resulting from the separation or abnormal growth of an active material due to repeated charge/discharge, thereby remarkably prolonging the cycle life of a lead-acid battery.
    Type: Grant
    Filed: December 24, 2002
    Date of Patent: February 10, 2009
    Assignee: Panasonic Corporation
    Inventors: Akihiro Maeda, Naoto Hoshihara, Junji Nakajima
  • Patent number: 7432014
    Abstract: The invention provides an anode capable of relaxing stress due to expansion and shrinkage of an anode active material layer associated with charge and discharge, or an anode capable of reducing structural destruction of the anode active material layer and reactivity between the anode active material layer and an electrolyte associated with charge and discharge, and a battery using it. The anode active material layer contains an element capable of forming an alloy with Li, for example, at least one from the group consisting of simple substances, alloys, and compounds of Si or Ge. An interlayer containing a material having superelasticity or shape-memory effect is provided between an anode current collector and the anode active material layer. Otherwise, the anode current collector is made of the material having superelasticity or shape-memory effect. Otherwise, a thin film layer containing the material having superelasticity or shape-memory effect is formed on the anode active material layer.
    Type: Grant
    Filed: October 20, 2004
    Date of Patent: October 7, 2008
    Assignee: Sony Corporation
    Inventors: Isamu Konishiike, Tomoo Takada, Kenichi Kawase, Yukio Miyaki
  • Patent number: 7398581
    Abstract: A method of making a plurality of battery plates includes forming a strip including a plurality of battery grids. Each battery grid includes a grid network bordered by a frame element and includes a plurality of spaced apart grid wire elements. Each grid wire element has opposed ends joined to one of a plurality of nodes to define a plurality of open spaces in the grid network. The method also includes deforming at least a portion of a plurality of the grid wire elements such that the deformed grid wire elements have a first transverse cross-section at a point intermediate their opposed ends that differs from a second transverse cross-section taken at at least one of their opposed ends. The method also includes applying a lead alloy coating to the strip, applying battery paste to the strip, and cutting the strip to form a plurality of battery plates.
    Type: Grant
    Filed: November 23, 2004
    Date of Patent: July 15, 2008
    Assignee: Johnson Controls Technology Company
    Inventor: Yu-Lin Chen
  • Patent number: 7314685
    Abstract: A titanium substrate having a thickened outer oxidation layer provided thereon by a treatment process performed either in an air atmosphere at elevated temperatures or through electrolytic oxidation (anodization), is discribed. The thusly conditioned titanium substrate serving as a cathode current collector for an electrode incorporated into an electrochemical cell exhibits improved electrical performance in comparison to the prior art techniques, i.e., electrically conducted carbon coated titanium screen and use of highly corrosion resistant materials, upon subsequent elevated temperature exposure.
    Type: Grant
    Filed: October 7, 2003
    Date of Patent: January 1, 2008
    Assignee: Greatbatch Ltd.
    Inventors: W. Richard Brown, Christine A. Frysz, Sally Ann Smesko, Esther S. Takeuchi
  • Patent number: 7247409
    Abstract: The hydrogen storage alloy electrode comprises: a conductive core material; and an active material layer which contains a hydrogen storage alloy powder and is carried on said core material, and the alloy powder has any shape selected from the group consisting of spherical shapes, substantially spherical shapes and oval shapes. The core material comprises: a conductive sheet; and fibrous or columnar sintered nickel pieces bonded to the surface of the conductive sheet. Alternatively, the active material layer comprises: an active material layer A which contains a hydrogen storage alloy powder A with a mean particle size “a” and is carried on said core material; and an active material layer B which contains a hydrogen storage alloy powder B with a mean particle size “b” and is carried on said active material layer A (wherein a<b). Alternatively, the active material layer further contains a crushed alloy powder having on the surface thereof at least one selected from the group consisting of nickel and cobalt.
    Type: Grant
    Filed: February 21, 2003
    Date of Patent: July 24, 2007
    Assignee: Matsushita Electric Industrial Co., Ltd.
    Inventors: Kazutaka Ikeda, Susumu Kikuyama, Akiko Miyahara, Kohji Yuasa
  • Patent number: 7223499
    Abstract: A grid is obtained by punching or expanding a sheet comprising a pure lead (Pb: 99.99 mass % or more) plate having a lead-tin alloy layer formed at least on one side of the pure lead plate. By using it as a positive electrode of a lead-acid battery, the problem that a pure lead grid shows bad charge acceptance characteristics after deep discharge can be solved, maintaining the excellent trickle life performance which a pure lead grid shows originally.
    Type: Grant
    Filed: November 5, 2002
    Date of Patent: May 29, 2007
    Assignee: GS Yuasa Corporation
    Inventor: Toshimichi Nakamura
  • Patent number: 7029797
    Abstract: An electrode plate for an alkaline storage battery of the present invention includes a conductive core material as a current collector, in which a plurality of through-holes are linearly provided in the core material so as to be parallel to a longitudinal direction of the core material, each through-hole having an aperture area of 10 mm2 or less and at least two pairs of opposite sides parallel to each other.
    Type: Grant
    Filed: May 17, 2002
    Date of Patent: April 18, 2006
    Assignees: Matsushita Electric Industrial Co., Ltd., Toyota Jidosha Kabushiki Kaisha
    Inventors: Naoto Sato, Nobuyasu Morishita
  • Patent number: 6953641
    Abstract: A method of forming battery grids or plates that includes the step of applying a lead alloy coating to a continuous strip of interconnected battery grids formed from a lead alloy grid material is disclosed. The battery grids may be formed by a continuous battery grid making process such as strip expansion, strip punching, or continuous grid casting. In one version of the method, the grid wires of a continuous strip of battery grids produced by a punching process are immersed in a melt of the lead alloy coating. In another version of the method, the grid wires of a continuous strip of battery grids produced by a punching process are deformed such that the grid wires have a cross-section other than the rectangular cross-section produced by the punching process and the strip of interconnected grids is immersed in a melt of the lead alloy coating. The method increases the cycle life of a battery.
    Type: Grant
    Filed: January 5, 2001
    Date of Patent: October 11, 2005
    Assignee: Johnson Controls Technology Company
    Inventor: Yu-Lin Chen
  • Patent number: 6895644
    Abstract: A battery positive grid is continuously cast of lead and thereafter cold worked to reduce its cross sectional thickness to change the microstructure of the lead and provide enhanced corrosion resistance and other properties needed for positive grids. The as cast thickness is reduced by not more than ½ or 2 to 1, to produce a positive grid with a lead weight of 0.5 to 2.1 grams per square inch of the area of the plan of the cold worked grid which improves the life of a battery in which it is used. A battery negative grid is continuously cast of lead and thereafter cold worked to reduce its cross sectional thickness 1.2:1 to less then 1.5:1 to increase the ultimate tensile strength needed for a lighter negative grid with a lead weight of 0.3 to 0.9 of a gram per square inch of the area of its plan.
    Type: Grant
    Filed: March 28, 2002
    Date of Patent: May 24, 2005
    Assignee: Wirtz Manufacturing Co., Inc.
    Inventor: John O. Wirtz
  • Patent number: 6884548
    Abstract: It is intended to provide a nonaqueous electrolyte battery that satisfies both of a large discharge capacity and a superior cycle life characteristic by developing a novel negative electrode material. A nonaqueous electrolyte battery uses a negative electrode active material that is a compound expressed by Formula (1): AzMXy??(1) where A is at least one element selected from the alkali metals, M is at least one element selected from the group consisting of Ti, V, Cr, Mn, Fe, Co, Ni, Cu, Ru, Rh, Pd, Os, Ir, Pt, and Mg, X is at least one element selected from the group consisting of B, N, Al, Si, P, Ga, Ge, As, In, Sn, Sb, Pb, and Bi, 0?z?20, and 0.2?y?6.
    Type: Grant
    Filed: December 27, 2002
    Date of Patent: April 26, 2005
    Assignee: Kabushiki Kaisha Toshiba
    Inventors: Hiroki Inagaki, Norio Takami, Tatsuoki Kohno, Tomokazu Morita
  • Patent number: 6875536
    Abstract: A composite hydrogen storage material including 1) an active material having hydrogen storage capacity; and 2) a catalytic material having greater catalytic activity toward the dissociation of molecular hydrogen and/or oxidation of hydrogen than that of said active material having hydrogen storage capacity. Also, a fuel cell employing anodes formed from the composite hydrogen storage material. The fuel cell has the ability to start up instantly and can accept recaptured energy such as that of regenerative braking by operating in reverse as an electrolyzer.
    Type: Grant
    Filed: August 12, 2002
    Date of Patent: April 5, 2005
    Assignee: Texaco Ovonic Fuel Cell LLC
    Inventor: Stanford R. Ovshinsky
  • Patent number: 6800398
    Abstract: 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: Grant
    Filed: June 13, 2001
    Date of Patent: October 5, 2004
    Assignee: Matsushita Electric Industrial Co., Ltd.
    Inventors: Satoshi Furuya, Gota Asano, Masaharu Miyahisa, Ayahito Shiosaki, Yoshihisa Inaba, Yoshiyuki Tada
  • Patent number: 6780543
    Abstract: A first lithium secondary battery of the present invention is formed by placing at least a positive electrode, a negative electrode, and a non-aqueous electrolyte in a battery case in which a positive electrode connecting member to which the positive electrode is connected and a negative electrode connecting member to which the negative electrode is connected are electrically separated, wherein said positive electrode connecting member is composed of clad material comprising one of aluminum or aluminum alloy and one of austenitic stainless steel or ferrite stainless steel, and the aluminum or aluminum alloy in the clad material is in the positive electrode side.
    Type: Grant
    Filed: January 9, 2002
    Date of Patent: August 24, 2004
    Assignee: Sanyo Electric Co., Ltd.
    Inventors: Seiji Yoshimura, Hiroshi Nakajima, Maruo Kamino
  • Publication number: 20040115530
    Abstract: The present invention relates to a lead-acid battery Comprising a positive and a negative electrode, each having a current collector comprising an expanded grid, characterized in that at least one of the positive electrode and the negative electrode contains an organic binder in an active material layer at an edge portion thereof.
    Type: Application
    Filed: October 21, 2003
    Publication date: June 17, 2004
    Inventors: Akihiro Maeda, Naoto Hoshihara, Junji Nakajima