WO1998037588A1 - Battery assembly with a monolithic separator unit - Google Patents

Battery assembly with a monolithic separator unit Download PDF

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Publication number
WO1998037588A1
WO1998037588A1 PCT/US1998/002602 US9802602W WO9837588A1 WO 1998037588 A1 WO1998037588 A1 WO 1998037588A1 US 9802602 W US9802602 W US 9802602W WO 9837588 A1 WO9837588 A1 WO 9837588A1
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WO
WIPO (PCT)
Prior art keywords
monoblock
tubular
battery assembly
cavity
battery
Prior art date
Application number
PCT/US1998/002602
Other languages
French (fr)
Inventor
Victoria A. Edwards
John L. Stempin
Original Assignee
Corning Incorporated
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Corning Incorporated filed Critical Corning Incorporated
Publication of WO1998037588A1 publication Critical patent/WO1998037588A1/en

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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/04—Construction or manufacture in general
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/40—Separators; Membranes; Diaphragms; Spacing elements inside cells
    • H01M50/463—Separators, membranes or diaphragms characterised by their shape
    • H01M50/469—Separators, membranes or diaphragms characterised by their shape tubular or cylindrical
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/10—Energy storage using batteries
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
    • Y02P70/50—Manufacturing or production processes characterised by the final manufactured product

Definitions

  • Porous separator units for storage batteries and battery assemblies embodying the separator units embodying the separator units.
  • a storage battery assembly customarily includes positive electrodes, negative electrodes, separators and an electrolyte.
  • the assembly may be either a sealed type battery, or a flooded type battery.
  • the electrodes are maintained in spaced relation by the separator.
  • the separator must have sufficient porosity to permit ion transfer between the electrodes. However, the pores should be relatively small, and tortuous to prevent dendrite growth that can cause a short circuit.
  • a rigid, porous separator offers distinct advantages both in battery performance and in manufacture.
  • the separator may provide structural support, whereas the electrodes are the primary source when flexible separators are employed.
  • the rigid separator has proven advantages, but also leaves room for improvement.
  • effort has been directed at further simplifying battery construction and assembly.
  • the present invention embodies results of such efforts.
  • the present invention resides in a battery assembly comprising electrodes, electrolyte and a separator unit, the separator unit comprising a monolithic, porous body containing electrolyte in its pores and having at least two parallel, elongated, spaced cavities, interior of and extending through the body, the electrodes being positioned within the cavities and having conductive current collectors attached.
  • the invention also resides in a separator unit comprising a monolithic, porous body having at least two parallel, elongated, spaced cavities internal of and extending through the body, the cavities being adapted to receive electrodes therein.
  • the invention further embodies a method of producing a battery assembly which comprises providing a material capable of being molded into a porous body, molding a quantity of the material into a monolithic, porous body with parallel, spaced, elongated cavities formed internal of and extending through the body, and positioning electrodes within the cavities.
  • FIGURE 1 is a top plan view of a slotted, monoblock separator unit in accordance with the invention.
  • FIGURE 2 is a view in cross-section along line 2-2 of FIGURE 1.
  • FIGURE 3 is a top plan view of a slotted, tubular monoblock separator unit in accordance with the invention.
  • FIGURE 4 is a view in cross-section along line 4-4 of FIGURE 3.
  • FIGURES 5, 6 and 7 are top plan views showing alternative, monoblock forms of the invention.
  • the present invention expands the concept of a separator unit. It envisions a separator unit that encompasses the electrodes, rather than simply separating them.
  • the separator unit is a monolithic body having elongated slots extending through a central portion of the body.
  • the slots form cavities which receive electrodes to form a battery assembly.
  • the monolithic body may be produced from a batch of proper viscosity by using a conventional molding process such as extrusion, pressing or injection molding.
  • a ceramic batch for molding a separator unit for a lead-acid battery may be prepared as a rigid body as disclosed in the Stempin et al. -494 patent.
  • the ceramic may be alumina, mullite, or mixtures thereof.
  • a rigid, porous, organic unit may be molded from a suitable organic polymer containing a pore-forming material and forming a rigid body.
  • suitable polymers include polyolefins, polyvinyl chloride (PVC), polyvinylidene difluoride (PVDF) and acrylonitrilebutadiene styrene (ABS).
  • PVC polyvinyl chloride
  • PVDF polyvinylidene difluoride
  • ABS acrylonitrilebutadiene styrene
  • the polymers may be made wettable. They may also be mixed with other materials, such as ceramics and/or wood pulp, to form composite materials that attain certain desired properties and/or reduce cost.
  • the monolithic separator structure may be used in either flooded or sealed, lead- acid type batteries as already referred to. It may also be employed in lithium cells or

Abstract

A battery assembly comprising a monolithic separator unit (10), the separator unit comprising a porous body containing an electrolyte and having at least two parallel, elongated, narrow cavities (12) extending into the body, the assembly further having electrodes (20) essentially filling the cavities and having conductive members.

Description

Figure imgf000003_0001
Form PCTISA/210 second sheet Jul 1992* INTERNATIONAL SEARCH REPORT International application No. PCT/US98/02602
C (Continuation). DOCUMENTS CONSIDERED TO BE RELEVANT
Category* Citation of document, with indication, where appropriate, of the relevant passages Relevant to claim No.
US 3,369,936 A (NOLL) 20 February 1968, col. 2, lines 1-26 and 1, 9, 15, and 16 Figs. 5-6.
Form PCT ISA/210 (continuation of second sheefχjuly 1992)*
BATTERY ASSEMBLY WITH A MONOLITHIC SEPARATOR UNIT
FIELD OF THE INVENTION
Porous separator units for storage batteries and battery assemblies embodying the separator units.
BACKGROUND
A storage battery assembly customarily includes positive electrodes, negative electrodes, separators and an electrolyte. The assembly may be either a sealed type battery, or a flooded type battery.
The electrodes are maintained in spaced relation by the separator. The separator must have sufficient porosity to permit ion transfer between the electrodes. However, the pores should be relatively small, and tortuous to prevent dendrite growth that can cause a short circuit.
Glass fiber mats are commonly used in commercial batteries. Microporous plastic sheets are also employed. Porous earthenware, sintered silicate sheets and honeycomb structures have also been proposed. United States Patent No. 5,514,494 (Stempin et al.) discloses and claims a rigid, porous, ceramic separator having a porosity of 40-90%, a pore size of 0.1-25 microns, a thickness of 1-12 mm. and resistance to acid attack. United States Patent Application S.N. 08/679,693, filed July 1 1, 1996 by T N. Gardner et al., discloses and claims a tubular, rigid, porous, ceramic separator for a rechargeable, deep-discharge battery assembly
A rigid, porous separator offers distinct advantages both in battery performance and in manufacture. In particular, the separator may provide structural support, whereas the electrodes are the primary source when flexible separators are employed.
The rigid separator has proven advantages, but also leaves room for improvement. In particular, effort has been directed at further simplifying battery construction and assembly. The present invention embodies results of such efforts.
SUMMARY OF THE INVENTION
In part, the present invention resides in a battery assembly comprising electrodes, electrolyte and a separator unit, the separator unit comprising a monolithic, porous body containing electrolyte in its pores and having at least two parallel, elongated, spaced cavities, interior of and extending through the body, the electrodes being positioned within the cavities and having conductive current collectors attached.
The invention also resides in a separator unit comprising a monolithic, porous body having at least two parallel, elongated, spaced cavities internal of and extending through the body, the cavities being adapted to receive electrodes therein. The invention further embodies a method of producing a battery assembly which comprises providing a material capable of being molded into a porous body, molding a quantity of the material into a monolithic, porous body with parallel, spaced, elongated cavities formed internal of and extending through the body, and positioning electrodes within the cavities.
PRIOR ART
Patents known to applicants and deemed relevant are described in a separate paper. BRIEF DESCRIPTION OF THE DRAWINGS
FIGURE 1 is a top plan view of a slotted, monoblock separator unit in accordance with the invention. FIGURE 2 is a view in cross-section along line 2-2 of FIGURE 1.
FIGURE 3 is a top plan view of a slotted, tubular monoblock separator unit in accordance with the invention.
FIGURE 4 is a view in cross-section along line 4-4 of FIGURE 3. FIGURES 5, 6 and 7 are top plan views showing alternative, monoblock forms of the invention.
BRIEF DESCRIPTION OF THE INVENTION
The present invention expands the concept of a separator unit. It envisions a separator unit that encompasses the electrodes, rather than simply separating them.
The separator unit is a monolithic body having elongated slots extending through a central portion of the body. The slots form cavities which receive electrodes to form a battery assembly.
The monolithic body may be produced from a batch of proper viscosity by using a conventional molding process such as extrusion, pressing or injection molding. A ceramic batch for molding a separator unit for a lead-acid battery may be prepared as a rigid body as disclosed in the Stempin et al. -494 patent. For acid resistance, the ceramic may be alumina, mullite, or mixtures thereof.
A rigid, porous, organic unit may be molded from a suitable organic polymer containing a pore-forming material and forming a rigid body. Suitable polymers include polyolefins, polyvinyl chloride (PVC), polyvinylidene difluoride (PVDF) and acrylonitrilebutadiene styrene (ABS). The polymers may be made wettable. They may also be mixed with other materials, such as ceramics and/or wood pulp, to form composite materials that attain certain desired properties and/or reduce cost. The monolithic separator structure may be used in either flooded or sealed, lead- acid type batteries as already referred to. It may also be employed in lithium cells or

Claims

4alkaline cells, such as Ni-Zn, Ni-Cd, Ni-MH, Zn-MnO2 providing a wettable alkali- resistant material is employed as the separator unit.The invention is further described with reference to the accompanying drawings wherein, FIGURE 1 is a top plan view of a slotted monoblock 10 of rigid, porous material.Monoblock 10 is shown as a ceramic, but might equally as well be a rigid, microporous organic, or a composite or mixed material.Monoblock 10 has elongated slots 12 which extend through the block. The slots may be open at both top 14 and bottom 16 of the block, but are closed at each side 18.Slots 12 will be molded just large enough for electrodes 20 to be inserted snugly therein.FIGURE 2 is a cross-sectional view taken along line 2-2 in FIGURE 1. This view shows paste-coated electrodes 20 occupying slots 12. In larger size batteries, a compliant layer might be inserted with electrode 20 to improve overall contact of the electrode with the separator. The use of such a compliant layer is described in detail in a companion application.FIGURE 3 is a top plan view of a slotted/tubular monoblock 30 of rigid, porous material. Monoblock 30 is shown with open slots 32 and 34 corresponding to slots 12 of FIGURE 1. Slot 36 has thin, parallel partitions 38 which extend through the slot. Partitions 38 define tubular cavities 40 in which tubular electrodes may be formed in the manner described in the Gardner et al. application noted earlier.As described in the Gardner et al. application, a tubular current collecting grid 42 may be centered in tubular cavity 40 with dry powder or wet paste 44 being packed around the grid to form an electrode. Tubular cavities 40 require an endcap 46 across the bottom of slot 36 to prevent active material shorting across the base. If monoblock30 is formed by pressing or injection molding, the endcap can be formed integral with the monoblock.FIGURE 4 is a cross-sectional view taken along line 4-4 in FIGURE 3. It shows a tubular electrode formed in cavity 40. FIGURES 5, 6 and 7 are top plan views showing alternative monoblock forms, a slotted cellular monoblock, a tubular monoblock and an I-beam, respectively. Regardless of the cavity structures, the monoblock must have the requisite separator properties of through porosity, wettability, tortuous pores for dendrite retardation, ability to retain electrolyte, durability against attack by the electrolyte and structural integrity. In addition to the apparent advantages already noted, the monoblock offers a variety of manufacturing advantages. The plates and separators in a battery are automatically aligned, a cell stack fits easily into a battery case since the monoblock governs size. In operation, cycle life and cell-to-cell uniformity are improved to increase life in a battery string. The monoblock concept is broadly applicable to different battery sizes and different battery chemistries. 6WE CLAIM:
1. A battery assembly comprising electrodes, electrolyte and a separator unit, the separator unit comprising a monolithic, porous body containing electrolyte in its pores, and having at least two parallel, spaced cavities internal of and extending through the body, the electrodes being positioned within the cavities and having conductive current collectors attached.
2. A battery assembly in accordance with claim 1 in which each cavity is occupied by a conductive grid that is paste coated.
3. A battery assembly in accordance with claim 1 in which at least one cavity is subdivided into a series of tubular subcavities by thin parallel walls extending through the cavity.
4. A battery assembly in accordance with claim 3 wherein each subcavity is filled with a paste and a current collector to form a tubular electrode member.
5. A battery assembly in accordance with claim 3 in which the base of the monolith has an endcap integral therewith.
6. A battery assembly in accordance with claim 3 in which one cavity is occupied by a negative plate electrode and an adjacent cavity is occupied by a tubular electrode.
7. A battery assembly in accordance with claim 1 wherein at least one cavity is occupied by a plate electrode having a compliant layer covering at least one face.
8. A battery assembly in accordance with claim 1 in which the monolithic body is uniformly porous throughout.
PCT/US1998/002602 1997-02-19 1998-02-12 Battery assembly with a monolithic separator unit WO1998037588A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US3889097P 1997-02-19 1997-02-19
US60/038,890 1997-02-19

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WO1998037588A1 true WO1998037588A1 (en) 1998-08-27

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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2019152531A1 (en) * 2018-01-31 2019-08-08 Keracel, Inc. Hybrid solid-state cell with a sealed anode structure
US10581111B2 (en) 2017-01-31 2020-03-03 Keracel, Inc. Ceramic lithium retention device
US10971760B2 (en) 2018-01-31 2021-04-06 Keracel, Inc. Hybrid solid-state cell with a sealed anode structure

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3369936A (en) * 1966-03-10 1968-02-20 Mc Donnell Douglas Corp Multiple plate battery
US3625770A (en) * 1969-06-02 1971-12-07 Mc Donnell Douglas Corp Flexible matrix and battery separator embodying same
US3625772A (en) * 1966-08-30 1971-12-07 Mc Donnell Douglas Corp Electrode-separator combination
US3625771A (en) * 1969-03-27 1971-12-07 Mc Donnell Douglas Corp Battery separator
US4279974A (en) * 1977-09-02 1981-07-21 Ngk Spark Plug Co., Ltd. Solid electrolytic material and use thereof
US5554464A (en) * 1995-07-26 1996-09-10 Corning Incorporated Honeycomb battery separator

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3369936A (en) * 1966-03-10 1968-02-20 Mc Donnell Douglas Corp Multiple plate battery
US3625772A (en) * 1966-08-30 1971-12-07 Mc Donnell Douglas Corp Electrode-separator combination
US3625771A (en) * 1969-03-27 1971-12-07 Mc Donnell Douglas Corp Battery separator
US3625770A (en) * 1969-06-02 1971-12-07 Mc Donnell Douglas Corp Flexible matrix and battery separator embodying same
US4279974A (en) * 1977-09-02 1981-07-21 Ngk Spark Plug Co., Ltd. Solid electrolytic material and use thereof
US5554464A (en) * 1995-07-26 1996-09-10 Corning Incorporated Honeycomb battery separator

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US10581111B2 (en) 2017-01-31 2020-03-03 Keracel, Inc. Ceramic lithium retention device
WO2019152531A1 (en) * 2018-01-31 2019-08-08 Keracel, Inc. Hybrid solid-state cell with a sealed anode structure
US10535900B2 (en) 2018-01-31 2020-01-14 Keracel, Inc. Hybrid solid-state cell with a sealed anode structure
US10971760B2 (en) 2018-01-31 2021-04-06 Keracel, Inc. Hybrid solid-state cell with a sealed anode structure
US11063302B2 (en) 2018-01-31 2021-07-13 Sakuu Corporation Hybrid solid-state cell with a sealed anode structure
US11165101B2 (en) 2018-01-31 2021-11-02 Sakuu Corporation Hybrid solid-state cell with a sealed anode structure
US11616254B2 (en) 2018-01-31 2023-03-28 Sakuu Corporation Hybrid solid-state cell with a sealed anode structure

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