JP2002532858A - Prism-shaped battery cell structure with stress-generating seal - Google Patents

Abstract

(57) [Abstract] A prism-shaped metal case having high strength, not deforming, and having resistance to leakage of an electrolyte is provided. The leak-resistant prism-shaped metal-air battery cells are formed by mutually engaged case members to form a prism shape. The case member forms a stress forming seal therebetween to prevent electrolyte and other components from leaking from the battery cell. The case member is separated by a seal member at a location where stress is generated. The stress is substantially axial, and the case member is shaped to create the axial stress. The inner case member is shaped with outwardly extending sidewalls to prevent twisting and improve electrical connection.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

TECHNICAL FIELD OF THE INVENTION

The present invention relates to a leak-proof structure for prismatic electrochemical cells, especially metal-air cells. More particularly, the invention relates to the construction of the case and internal components, and to a method of assembling a battery to form a stress forming seal.

[0002] This application is related to US patent application Ser. No. 09 / 293,45, filed Apr. 15, 1999.
8 and U.S. Patent Application No. 60 / 112,29, filed December 15, 1998.
A priority under No. 2 has been claimed.

[0003]

[Prior art]

Advances in the use of small power devices have highlighted the need for electrochemical battery cells that can supply large amounts of power in a small space. In these devices, studies of leak resistance and the development of lightweight containers that can store, for example, the chemical and other internal components of the battery cell and provide adequate electrical internal connections and connections to the device. Research is required. Consumer demands for these devices are due to the considerable limitations of battery design size and weight in relation to pure shape as well as volume. To provide maximum energy in the allocated space, the arrangement of battery cells or closely packed battery cells is substantially the same as the predetermined space, minimizing wasted space and maximizing stored energy. It is necessary. Since many electrical devices are designed to house batteries that are approximately square in shape, prismatic cells are particularly suitable for powering these devices.

[0004] Further, in order to reduce the weight of the battery cell, it is preferable that the toner is made of a thin and lightweight material. In many batteries, containers are composed of small pieces of many cell weights. Since electrochemical cells have strict requirements on the design of the cell housing, the need to minimize material thickness must be balanced with the need for strength.

The present invention relates to a prism-shaped battery cell having a case at least partially formed of a metal or a material that can be deformed similarly to a metal. The advantages of using a metal case include the well-known cost, manufacturability, strength and accuracy features that metal provides,
Including the use of the case as the whole electrode.

[0006] In certain electrochemical cells, external and internal forces create significant loads that need to be countered or compensated. For example, in a zinc-air battery cell, oxidation of the anode zinc, which produces current, causes significant anode expansion. 60%
Up to volumetric volume increase has been reported. Hydrogen is generated by a parasitic reaction between the alkaline electrolyte of the cell and zinc. Hydrogen is also generated during battery shutdown. If the battery cell cannot be evacuated with proper efficiency, the generated hydrogen further increases the internal stress of the battery cell. The increase in internal stress impairs the mechanical integrity of the cell case, causing electrolyte leakage and short circuits, and potentially explosion.

[0007] In order to solve these problems, for example, known metal kale designs (for example,
The button cell comprises two main case members, which are insulated from one another by grommets or other sealing members arranged between the case members. The grommet prevents the case members from contacting each other and also effectively seals the electrolyte in one part of the cell from the other parts of the cell. However, when the case is deformed, the size of the gap provided with the grommet changes, and the electrolyte reaches around the grommet and leaks from the gap.

In some battery cells, particularly metal-air battery cells, the surface of the battery cell has small air access holes to allow gas exchange. In metal-air battery cells, atmospheric oxygen reacts with the anode metal to generate a current. The pores provide a means for atmospheric oxygen to enter the battery cells. One of the dangers of having pores in the cell is that the electrolyte may leak out of the battery cells through the pores. Furthermore, the risk is increased by the possibility of increasing the internal stress of the case.

If the metal case members come into contact with each other or come into contact with electrode materials of different polarities inside the cell, deformation of the case results in a short circuit. Also, deformation of the case may cause disconnection of the electrical connection between the battery cell and the electrical device. Changes in battery cell size can cause disconnection between the electrodes and the electrical contacts of the electrical device.

In order to solve this problem, battery cell designers have conventionally produced metal cases having a substantially cylindrical shape. Such button cells are inherently strong and are commonly used for power monitoring and hearing aids. The forces acting on the main surface of the button cell are countered by the inherent strength of the cylindrical structure.

In FIG. 1, the button cell 10 has a higher internal stress at ambient pressure. The button cell 10 has two main case members 12, 14, which are joined to form a button-shaped enclosure. The outer curved portion 16 has the shape of the outer case member 12 on the inner case member and prevents the two case members 12, 14 from separating. The internal stress represented by the force F1 presses the two case members 12, 14 in a direction to separate them from each other. The separating force F1 is opposed by a force F2 acting on the two case members 12, 14. Since the cases 12, 14 are each cylindrical, the forces F1, F2 are resisted by the characteristic hoop strength of the small diameter portion of the curved portion 16 of the outer case member 13. Further, even the distribution of the force can be performed by the case members 12 and 14.
Ensure a uniform seal between them.

Due to its cylindrical shape, an advantage of the button cell is the hoop strength of the vertical wall. FIG.
The button cell 20 has two case members joined to each other. The inner and outer case members each have side walls 22, 24 between which the grommets 26 are located.
Is arranged. When a high stress F3 acts on the button cell 20, the side walls 22, 24
Will vary in size. (The size of the inner wall 22 changes due to the force of the internal stress, and the size of the outer wall 24 changes due to the force exerted by the inner wall 22 via the grommet 26.) However, the grommet 26 sufficiently seals the case members together. The stress and tension on the side walls 22, 24 are each uniform around the perimeter of the case, and the side walls 22, 24 effectively resist the tension caused by internal stress.

Unlike the button cell of FIG. 2, the sidewalls of the prism-shaped cell do not experience the same uniform stress and tension. In FIG. 3, the square prism-shaped cell 30 also has two case members, the inner case member has 40 sidewalls 32, the outer case 34 has four sides 34, and the grommet 36 has side walls. 32, 34 are arranged. When a relatively high internal stress F4 acts on the prism-shaped cell 30,
The side walls 32, 34 are twisted because the cylindrical shape lacks the inherent strength required to resist deformation. Due to the inherent properties of the prism-shaped cell 30, the sides 32, 34 do not maintain that shape. The center of the long side wall tends to deflect significantly from its initial position, causing large deformation and leakage problems. Side wall 32 of prism-shaped cell 30
, 34 can vary considerably as compared to the pull around the periphery of the button cell 20 of FIG.

Due to these problems, despite the obvious advantages in package density, non-button shaped battery cells have not heretofore been manufactured commercially.
That is, a square prismatic battery cell can fill a normal linear battery container design with a much higher package density than a button cell, making the use of a button cell unattractive. I do. The solution to the inherent disadvantages of prismatic cells must be dealt with before prismatic battery cells become commercially viable.

In a prism-shaped cell, the deformation of the case causes various problems. Unlike a button-shaped battery cell, the force resulting from the increase in internal stress is not distributed uniformly around the cell periphery of the prism-shaped cell, or cannot be sufficiently resisted by the hoop strength. The prism-shaped cells have a sufficiently long spacing between corners. The long spaced wall portions of such prism-shaped cells are inherently weak and may be deformed.

In the prior art example shown in FIG. 4 and similar to US Pat. No. 5,662,717, a metal-air button cell 40 includes two harmonious inter-engaging case members 42, 52. The cathode and anode case members 42, 52 each have substantially cylindrical side walls 46, 56, a main wall structure or base 48, 58, and peripheral corners located between the walls 46, 56 and the bases 48, 58. 50, 60 and peripheral edges 44, 54 forming openings of the case members 42, 52. These case members 42, 52 are assembled such that the bases 48, 58 are positioned opposite to each other and form opposite charging surfaces of the battery cell 40. The grommet 62 disposed between the side walls 46 and 56 is electrically insulated, seals the case members 42 and 52, and the approximately 45-degree bent portion 43 of the cathode case member 42 forms the case members 42 and 52. We prevent coming off.

In the prior art example, the outer edge 54 of the anode case member 40 is often shown in a sharp shape resulting from a cutting operation in a manufacturing process. This sharp edge 54
Can penetrate the grommet 62 and damage the grommet 62, causing a risk of electrolyte leakage and short circuit. Still further, in a zinc-air battery cell, the case member is fabricated in a three-layer nickel-stainless steel-copper cladding, and these metals are separated from the zinc anode by a coating or film. When these tri-layer cladding metals are exposed to a zinc anode, all of the tri-layer cladding metal reacts chemically, generating hydrogen or introducing contaminant ions into the electrolyte. Coatings or films suppress these reactions. However, cutting operations in the manufacturing process may expose the underlying nickel and increase the rate of reaction.

The prior art example of FIG. 4 also shows the side walls 46, 56 of the case members 42, 52 that are perpendicular to the main surfaces 48, 58, respectively. In other words, the side walls 46, 56 are parallel. One problem with this configuration relates to the assembly of the battery cell 40. Since the internal components are located at the bottom of the cathode case member 42 (near the base 48), the components must be lower than the overall height of the side walls 46. The dimensional tolerances in the components of the case member will cause the components to stack or deflect when moved to their final position.

The prior art example of FIG. 4 also shows a grommet 56 located between the smooth surfaces of the case members 42, 52. As already clear, many different electrolytes,
For example, KOH can easily flow across metal surfaces. Case member 4
The surface scratches 2 and 52 may function as a channel through which the electrolyte moves and finally leaks out of the battery cell 40.

US Pat. No. 5,537,733 describes a method for producing a square nickel-metal hydride secondary cell, and US Pat. No. 5,556,772 describes a prism-shaped case for a lithium iron type cell. Have been. These patents point out features but do not suggest a prism-shaped cell.

US Pat. Nos. 4,374,909 and 4,656,104 relate to cases for metal-air button-type battery cells. This patent does not suggest a solution for achieving a prismatic, high strength metal case that may be utilized in metal-air battery applications.

In fact, the above-mentioned patents do not suggest or describe how the geometric features of the container increase strength and reduce or prevent unwanted deformation or expansion.

[0023]

DISCLOSURE OF THE INVENTION The present invention provides a prism-shaped metal case having a feature of forming a case having high strength, being hardly deformed, and having resistance to leakage of an electrolyte.

[0024]

[Means for Solving the Problems]

Depending on the shape of the case member and through the process of bending or bending, the case member is engaged to create stress on the case member, sealing the case member to prevent leakage of electrolyte in the case and separating the case member. Is to be prevented. The stress generated by the case member is preferably in the axial direction.

For example, the present invention is applied to an inner case having a side wall, and the side wall extends outward from a main surface toward an outer edge thereof to provide a high-strength structure to the battery cell, and to provide the case member with crush resistance. And protects other parts of the battery cell from damage due to sharp edges that may be deformed on the case member. The present invention also includes a bend on the outer case member to form a stress seal, and also includes a step for forming the bend. Bending over 90 degrees beyond a relatively small radius of curvature not only increases the strength of the case member, but also creates an almost axial stress on the inner case member, preventing separation of the case member It is supposed to. A recess in the main surface of the inner case member can be provided away from the bend portion of the outer case member to apply a bend greater than 90 degrees and to provide additional strength to the battery cells.

The present invention also provides a feature that makes the battery cell highly reliable, inexpensive, and suitable for mass production. The formation of bumps on the outer and inner flat surfaces of the battery cells provides additional strength to the case. These bumps eliminate or reduce the tendency of the battery cells to expand due to increased internal stress in the cells. The side wall of the case member extends outwardly from the flat surface, preventing the side wall from being crushed inward and making it easier to assemble the battery cell. The side wall is shaped to provide an excellent seal between the case members to prevent leakage of the electrolyte. Tar or other liquid type sealant is applied to the grommet disposed between the case members to prevent leakage at the station. The grommet separates the two cases and insulates them. Further, the ring of the diaper located between the case members is adapted to absorb the electrolyte which will continue to act on the grommet.

The case member has a liquid receiving portion or a catch pot structure portion, and receives an adhesive or an electrolytic solution that continues to act on the separator. This pot structure also provides an inexpensive means of ensuring that the air electrode maintains electrical connection to the cathode case member. This pot structure eliminates the need to manufacture a case member having sharp internal corners. The shape of the pot structure further increases the strength of the case member.

The present invention increases the strength and durability of a metal-air battery cell having two air cathodes. Due to the inherent differences between the two cathodes of a battery cell, different or improved solutions are needed.

The present invention will now be described with reference to the accompanying drawings, with reference to one embodiment and a plurality of examples, which embodiments limit the invention to certain embodiments. It is not intended. On the contrary, the intention is to cover all modifications, improvements and equivalents that may be included within the scope of the invention as defined by the appended claims. Accordingly, the description and examples of the preferred embodiments of the invention are merely illustrative of the invention. Particular embodiments are set forth to illustrate and schematically illustrate preferred embodiments of the present invention. Although the embodiments are described with reference to metal-air battery cells, the invention is not limited to this type of battery cell. In addition, the present invention can be applied to alkaline battery cells and other initial battery cells. A prism-shaped metal-air battery cell is illustrated in the description of the present invention, as a metal-air battery cell is particularly suitable for describing many features of the present invention. Although the embodiment will be described with reference to a square battery cell, the present invention is not limited to a battery cell having a square case. The present invention is not limited to hexagons and octagons, but can be applied to all prism-shaped cells including other cells each having a case having straight side walls.

The particular embodiments are provided for the reason that the principles and features of the present invention will be most likely to be most readily and easily understood. In this regard, the detailed structure of the present invention is not shown in more detail than necessary for a basic understanding of the present invention. The description given with reference to the drawings is made to show those skilled in the art how several forms of the present invention may be implemented.

[0031]

BEST MODE FOR CARRYING OUT THE INVENTION

8A and 8B show prism-shaped metal-air battery cells 100 after assembly.
The battery cell 100 has two main case members, an anode case member 10.
2 and a cathode case member 104. The case members 102 and 104 are substantially rectangular tray-shaped case members, and have a main wall structure or bases 110 and 112.
, Continuous sidewalls 114, 116 extending to corners 106, 108, bases 110, 1
It has a bend between the rim 12 and the side walls 114, 116, and peripheral edges 118, 120. In this embodiment, the bent portion of the anode case member 102 is
42 and the peripheral rim 140, and the bent portion of the cathode case member 104 is the peripheral shelf 1
32 and a peripheral pot structure part 134.

The inside of the enclosure formed by the case members 102, 102 is an internal component of the cell 100, and includes a metal anode 122, an air cathode 124, a separator 126, and a diffuser 128. The insulated grommet 130 separates the side walls 114 and 116 of the case members 102 and 104, and separates the case members 102 and 104.
104 are prevented from contacting each other. The grommet 130 protects the air cathode 124 from the anode case member 102 and
, 104 are sealed. An anode current collector (not shown) electrically connects metal anode 122 to anode case member 102, and a cathode current collector (not shown) electrically connects air cathode 124 to cathode case member 104.

The case members 102, 014 are engaged with each other, and the engaged state is maintained by partially bending the side wall 116 of the cathode case member 104 around the anode case member 102, preferably by a bending process. Assembling process is grommet 130
And the case members 102 and 104 generate pressure stress, which is applied to the battery cell 100.
Seal. This stress is initially drawn by axial forces during and after the completion of the assembly process due to the shape of the case members 102, 104. This stress persists, at least in part, after the assembly process and a seal is achieved.
Further, the air cathode 124 further includes the air cathode 124 and the cathode case member 1.
One or two layers of Teflon (R) sealing to 04 may be included. The stress will be described later in detail throughout the assembly process.

The cathode case member 104 of the battery cell 100 has features of increasing strength and improving reliability and manufacturability of the battery cell 100. 9 and 10 showing the uncurved cathode case member 104 before assembly, the peripheral shelf 1
32 and peripheral bowl structure 134 increase the strength and rigidity of case member 104 and also provide the reliability benefits described below. The shelf 132 and the pot structure 134 increase the strength and rigidity of the cathode case member 104 by distributing a part of the load to the stronger curved corner 108. This load is due to drag against external or internal stress. It should be noted that the pot structure 134 helps to prevent the collapse shown, for example, in FIG.

For example, in FIG. 11, which shows a perspective view of a cut portion of the case member 104, the bending moment that would be formed by the force F applied to the center of the span and resisted by the fixed support point S, 132 and the bent portion of the pot structure 134. The shelf 132 and the pot structure portion 134 are located on the shelf 13 including the vicinity of the corner 108.
2 and the force around the area of the pot structure portion 134 to increase
Disperse the concentrated stress acting on one area. When a load is applied to the case member 104 along one of its long span walls, the case member 104 will have rounded corners 108.
By transmitting a part of the load to the bearing, deformation can be prevented.

In FIGS. 9 and 10, the side wall 116 of the cathode case member 104 that is not curved extends from the peripheral pot structure portion 134 to the edge 120. This outward extension will aid in the manufacture of the metal-air battery 100 by simplifying the placement of internal components on the cathode case member 104 for the manufacturer. This spread serves to guide the parts during assembly and allows the insertion of the parts without distorting these parts. This feature is particularly advantageous when inserting an air cathode, since the air cathode is very delicate. Cathode case member 1
The size of the area of the opening 04 is larger than the size of the area of the bottom of the cathode case member 104, so that the internal components of the battery cell 100 can easily slide in the cathode case member 104. When the battery cell 100 is fully assembled, a bend or bend process, although not necessary, removes the spread and forms the sidewalls 116 substantially perpendicular to the main surface 112 and the peripheral shelf 132.

As shown in FIG. 8A, assembly of the battery cell 100 requires that the cathode case member 104 be at least partially curved or bent with respect to the anode case member 102. However, bending the edge 120 with respect to the corner 106 of the anode case member 102 forms wrinkles on a part of the cathode case member 104, which deteriorate the sealing performance of the electrolyte. To reduce wrinkles and the negative effects of wrinkles, the cathode case member 104 can be formed of a very soft or annealed metal where wrinkles are likely to occur. In some cases small wrinkles will be tolerated.

Referring now to FIG. 12A, in another embodiment, a notch 136 is formed near the corner 108 of the cathode case member 104 to reduce the amount of excess material when the edge 120 is bent. Excess material forms wrinkles and impairs sealability. Further, when the surplus material presses the elastic layer, the anode case layer 102 is elongated and an electric bridge is formed, which may cause a short circuit of the battery cell 100. Notch 136 solves this problem by reducing the amount of excess material.

According to FIG. 28B, in another embodiment, the reduction of excess material to prevent wrinkles and short circuits can be achieved by pressing down the pot structure 134 at a portion near the corner 108. . The figure exaggerates the effect. For example, when the depressed portion is formed by a pressing process, excess material is removed from the wall 116 by the pot structure portion 134.
At the corner 108, essentially reducing the height of the wall.

In another solution to the wrinkle problem, the cathode case member 104 has its edge 1
20 can be bent to different sizes. The case member 104 can be bent slightly further along side portions of the case member and along corner portions. In FIG. 12C, the corner portion 13 of the cathode case member 104
9 is not bent to the same extent as the portion along the side of the battery cell 100 with respect to the anode case member 102, and causes the edge 120 to slightly rise at the corner portion 139. This solution reduces wrinkles by reducing the amount of deformation in the vicinity of the corner portion 139, but sufficiently seals the case members 102, 104. The effect of reducing the curvature at the corner can be understood from the cross-sectional views in FIGS. 12D-1 and 12D-2. FIG. 12D-1 shows a partial cross section of a side portion of the cell, and FIG. 12D-2 shows a partial cross section of a corner portion of the same cell.

Returning to FIG. 10, the air access holes 138 on the metal-air battery cells cause electrolyte leakage. The base 112 of the cathode case member 104 has a plurality of air access holes 1 of a size and area sufficient to ensure sufficient contact of the air cathode with oxygen.
38. Oxygen is needed to generate an electric current in the battery cell 100. Increasing the size of the air access holes can increase the supply of oxygen to the air cathode. However, large air access holes 138 increase the likelihood of electrolyte leaking through air access holes 138 and increase the rate at which metal anode 122 dries. Large air access holes 138 will allow the electrolyte to pass freely, while small air access holes 138 will restrict flow through holes 138. The surface tension of a liquid or gel, such as an electrolyte, will prevent the electrolyte from passing through the small air access holes 138.

Air access holes 138 having a diameter of 0.4-0.5 mm can be repeatedly drilled in a metal case 0.1-0.4 mm thick without excessive maintenance of the punch. Holes 138 of smaller dimensions have proven to be difficult to drill.

Appropriate attempts to provide adequate air access while limiting excessive drying and electrolyte leakage in the design of the cathode case member 104 are made through experimentation. The use of a suitably sized air hole 138 allows the use of a suitable, fixed size of the metal-air battery 10 when using various cathode case members 104 having a variety of fixed distances between each air hole 138. Energy can be determined. As the density of the air holes 138 increases, the number of air holes 138 that can be formed on the base 112 increases, and the total current generated by the battery cells 100 also increases. However, at some point the total current is reduced or constant.
This occurs when the area provided by each air hole 138 substantially overlaps the area provided by an adjacent air hole 138. In addition, increasing the density of the air holes 138 will unnecessarily increase the rate at which the battery cell 100 dries with little contribution to the supply of oxygen to the air cathode 124.

Reducing the spacing of air holes 138 increases the number of air holes 138 and increases the likelihood of electrolyte leakage. Fewer or smaller air holes 138 are air holes 1
The likelihood of electrolyte leaking through 38 is reduced.

Further, the anode case member 102 has a feature of increasing its strength and improving the reliability of the battery cell 100. In FIG. 13, the peripheral rim 140
And the peripheral trough 142 increases the strength and rigidity of the case member 102 in substantially the same manner as the shelf 132 and the recess 134 of the cathode case member 104. The rim 140 and the trough 142 disperse the concentrated stress around the corner 106 of the anode case member 102.

In the conventional example of FIG. 5, the design of the side wall 56 of the anode case 52 tends to be crushed due to an external force. Side walls parallel to each other cause collapse. Now,
In FIG. 6 showing the collapse of the battery cell, the side wall is bent such that the peripheral edge 54 is deflected inward. This collapse is caused by an external force applied during the bending process or expansion of the base 54 of the anode case member 52. In button cells, the strength of the cylindrical shape can withstand this type of deformation. In a prism-shaped cell, the shape cannot be completely resistant to deformation.

Referring back to FIG. 13, it is necessary that the cell wall 114 endure an extreme force due to the axial force caused by bending. The expansion of the anode case member 102 is performed on both the case walls 114 and 116.
To cooperate to support the cell 100. The outward spreading engages the base 112 of the cathode case member 104 to ensure that no bending of the type shown in FIG. 6 occurs.

Also, the outward spreading can improve the electrical connection between the cathode collector (not shown) and the cathode case member 104, and can improve the effectiveness of the separator 126. The peripheral rim 144 of the anode case member 102 presses the separator 126 and the air cathode 124 via the grommet 130 by the axial force during the assembly process. Also, the axial force bends the sloped side walls 114 and the ends of the walls outward, which presses the edges of the air cathode 124 and the separator 126 toward the cathode case member 104, causing a gap between the cathode current collector and the case member 104. This improves the electrical connection.

When the edge of cathode 124 is pressed toward case member 104, a cathode current collector (not shown) forms a good electrical connection with case member 104.

In FIG. 13, the shape of the peripheral rim 144 increases reliability by protecting the grommet 130. The rim 144 has an axial force that makes the rim 144 grommet 130
The peripheral edge 118 is directed away from the grommet 130, which may be damaged when pressed towards. These axial forces are present when the battery cell 100 is assembled and after the assembly.

The cutting and drilling steps performed to form the case member 102 can form sharp edges 118 that can damage the grommet 130 by cutting into and cutting the grommet 130. There is. To protect the grommet 130, the rim 144 is shaped such that the edges 118 do not bite into the grommet 130, but rather the smooth surface of the rim 144 presses on the grommet 130, thereby extending over a large area where axial forces meet. It is being distributed.

FIGS. 14 to 18 show another example of the rim 144 having a different shape. In FIG. 14, the rim 145 has a bend of approximately 180 degrees, and the edge 118 is further away from even the portion of the grommet that could be damaged. In FIG. 15, the rim 146 has a bend in the opposite direction or inward. In this embodiment, the cathode case member 104 need not be shaped to accommodate the space occupied by the outward projection of the rim 146. The grommet 130 can be thinned and the anode case member 102 can be sized to hold most of the metal anode 122. In FIG. 16, the rim 147 has a shape having two bent portions. The rim 147 offers the advantage of utilizing a thinner grommet 130 and a larger volume of the anode case member 102 as in the previous embodiment. In addition, the rim 147 increases strength and stiffness through its multiple bends, reducing the likelihood of collapse. Furthermore, rim 147 protects against undesired chemical reactions between case member 102 and metal anode 122. As mentioned above, case members made of nickel-steel-copper three-layer cladding react with the zinc anode to generate hydrogen or introduce contaminant ions into the electrolyte. Nickel is usually coated to prevent unwanted chemical reactions. However, nickel becomes exposed at edge 118 during molding of case member 102. In this embodiment, rim 147 includes edge 118 and metal anode 122
There is a distance between them. According to FIGS. 17 and 18, in other embodiments the edges are smooth and rounded so as not to include sharp edges.

In FIGS. 13 and 19, the base 110 of the anode case member 102 has a ridge 146, which extends from one peripheral trough 142 on one side to the peripheral trough 142 on the other side. Although not shown, the cathode case member 1
The base 112 of 04 can have a ridge as well. These bumps 146 increase the stiffness of the base 110 and reduce the likelihood of deformation of the case member 102 under increased internal stress.

The bump 146 of the anode case member 102 applies an external force on the base 110 to the rim 140.
And to the trough 142 to increase the strength. These bumps 1
46 can be formed simultaneously when the cathode case member 104 is bent over the anode case member 102 by a suitably designed bending tool. Cold working of the ridges 146 on a thin, relatively flat metal surface, such as the main surface 110, forms ridges 146 on both sides of the metal surface, further increasing the strength of the base 110.

FIGS. 20, 21 and 22 show other examples of bumps. FIG. 20 and FIG.
1 shows two different arrangements of bumps 148,150. FIG. 22 shows the anode case member 102 having the ridge 152 fixed to the inner surface. The ridge 152 is relatively thin so as to limit its occupied space, thereby leaving a large space for the metal anode. Also, these bumps 152 increase the strength of the side wall.

In the conventional example shown in FIG. 4, the bent portion 43 has an inherent strength due to the shape of the cell 40. Deforming the cylindrical member so that the edges are bent inward creates a very large hoop that resists tension. The bend 43 can then resist deformation and detachment of the case members 42, 52 due to its hoop strength. Further, as described above, the battery cell 40 maintains the sealing performance by distributing a force around the periphery of the battery cell 40.

However, not all of the unique advantages of button cells are reproduced in prism-shaped cells. For example, similar bends in prismatic cells do not provide the same strength and rigidity characteristics as button cells. If the case member is bent on the long straight sides, it can easily be straightened towards its original position.

In addition, as shown in the embodiment of FIG. 4, bending at only 45 degrees can reduce the aforementioned lack of stress deformation, the size of various types of battery cells, and the springback effect of the metal when bent. Not a specific strength to consider. For example, when the bending 43 of the cathode case member 42 causes springback and the side wall 46 starts to spread outward, the two case members 42 and 52 come off. Cathode case member 42
Simply increasing the bending angle does not solve all of the problems, because the edges 44 of the substrate cause wrinkles and cause electrolyte leakage. Further, increasing the bending angle causes a contact between the cathode case member and the anode case member to cause a short circuit.

US Pat. No. 5,432,027, entitled “Button Battery with Bendable Structure and Angled Button Battery,” also does not solve the problems inherent in prismatic cells. This patent relates to a thin button cell that can be deflected without impairing the function of the button cell and without impairing the perimeter seal. In FIG. 7, which shows a partial cross section of the bent portion of the above-mentioned patent, the case members are held together by a C-shaped fluid type bent seal. This seal has been found to be effective for very thin battery cells with no or very short side walls, and has no particular effect for thin prismatic cells. Very thin button cells do not apply to the effect of thin and expanded battery cells, and the inner case member is
This may cause the character to slip out of the bent portion or to open the bent portion. further,
The C-shaped bend occupies excessive space in the lateral direction, thereby reducing the main advantage of prismatic cells.

Returning to FIG. 8A, to assemble the battery cell 100, the cathode case member 104 is bent or bent on the peripheral rim 140 of the anode case member 102 to form a bent portion 154. Due to the ductility of the metal, the cathode case member 104 tends to spring back when bent. The bending or bending step is to deform the material well beyond its ductility limit, but there is some ductility restoration. To restore ductility and avoid side effects that are detrimental to seal reliability,
The bend 154 should be under heavy tension. In the embodiment of FIG. 8A,
Side wall 116 also includes a bend 155 that accommodates the outward projection of rim 144.

The bent portion 154 prevents the case members 102 and 104 from being disconnected. By bending or bending case member 104 sufficiently such that a portion of bent portion 154 extends toward base 112, bent portion 154 causes cathode case member 104 to be bent.
Is prevented from being disconnected, and the case members 102 and 104 are prevented from being detached. The protrusion of the rim 140 of the anode case member 102 and the thinness of the grommet 130 prevent the bent portion 154 from deflecting laterally. In essence, the bend 154 hooks into the rim 140 to prevent the sidewall 104 from being pushed out.

The bending step can be achieved by further bending the peripheral pot structure 134 by a pinching step such that the outward extent of the sidewalls 116 is reduced or eliminated. Next, the anode case member 102 is pressed toward the cathode case member 104, while the cathode case member 104 is curved about the peripheral rim 140 by a similar sandwiching process.

In order to reduce the harmful effects due to the restoration of ductility when the cathode case member 104 is bent, the anode case member 102 is strongly pressed toward the cathode case member 104, and the grommet 130 is positioned. It should be pressurized at 156,158. When the grommet 130 is pressurized and the cathode case member 104 is curved, the sealing performance of the battery cell 100 can be improved. Case members 102, 10
Any gaps that may form when springback occurs on the cathode case member 104 between the grommet 130 and the grommet 130
Can be filled by the elasticity of Even after the cathode case member 104 has springbacked, the grommet 130 is at least partially pressurized at locations 156, 158, and a tight seal is maintained at that location. The elasticity of the grommet 130 forms a seal.

The grommet 130 is preferably shaped such that a space 131 filled with air is formed between the seal near the cathode 156 and the seal near the edge of the cathode portion of the cell case 158. If there is no gap 131, the electrolyte controlled to continue acting on the seal at position 156 will be moved to the seal at position 158 due to the effect of capillary action. This void 131 ameliorates or eliminates this capillary effect by enlarging the channel sufficiently to allow the electrolyte to flow.

Although not shown, the side wall 116 of the cathode case member 104 may be further curved so as to bend inward. Further bending increases the internal stress and ensures that the case member 104 does not peel back from the peripheral rim 140 when the battery cell 100 begins to expand. Also, large bends can counter the tendency of the battery cell 100 to expand on the side walls 114, 116 by compensating for the increased stress. In addition, such bends increase the interacting forces between the side walls 114, 116, thereby improving the effectiveness of the grommet 130 and increasing the battery cell 1
Seal 00. Greater forces between the grommet 130 and the side walls 114, 116 form a better seal.

The elasticity of the grommet 130 also ensures that a seal is maintained between the air cathode 124 and the peripheral ledge 132. The air cathode 124 can include an unstressed substantially flat layer of Teflon on the side facing the base 112. When the battery cell 100 is assembled, the unpressurized Teflon layer is pressed against the shelf 132 to form a seal and the electrolyte is allowed to flow through the air access holes 1.
Prevent escape through 38. Unpressurized Teflon is particularly suitable due to its gas permeation properties. However, Teflon has little elasticity. The portion of the layer of Teflon contacting the shelf 132 continues to be at least partially pressurized when an axial force appears. Accordingly, grommet 130 should continually press air cathode 124 toward shelf 132 to ensure that the seal is maintained.

A substantially flat layer of unstressed Teflon® is not required and can be replaced with a flat piece of Teflon®.
In FIG. 22A, a Teflon® ring 190 is placed over the shelf 132 and is shaped to cover the shelf 132. Also, the Teflon ring 190 can be fixed to the air cathode 124,
As a result, the Teflon link 190 is connected to the air cathode 124 and the shelf 132.
And placed between.

In other embodiments, the air cathode 124 can have a substantially flat layer of unpressurized Teflon® and a Teflon® ring 190 secured to the flat layer. The two layers of Teflon further improve the seal between the air cathode 124 and the shelf 132. Also, Teflon ring 190 removes one layer of Teflon between air cathode 124 and diffuser 128. The unnecessary layer of Teflon acts as a barrier between the air cathode 124 and the air access holes 138,
Access to oxygen by the battery cell 100 can be restricted.

Unlike the button cell, which can resist deformation and detachment of the case member due to its hoop strength, the prism-shaped battery cell 100 of the present invention has a substantially axial direction between the case members 102, 104. Resists disengagement by the force of the interaction.

23 and 24, the cross section of the bent portion 154 substantially matches the shape of the rim 140, and the case member 104 has a lateral or non-axial force of the interaction force acting near the bent portion 154 and the rim 140. Directional components cancel each other out. The axial component of the remaining force presses the anode case member 102 toward the cathode case member 104. For example, the bend 154 is the peripheral rim 1 indicated by the forces F10X F11X.
Acts on a force above 40. The transverse components of the forces F10X F11X are approximately equal and opposite. The sum of the axial components of the forces F10X and F11X is opposite to the sum of the axial forces F12 that the anode case member 102 acts on the cathode case member 104.

If the transverse component of the force is not substantially canceled, or if the bend 154 does not substantially match the rim 140, the battery cell 100 will deform and electrolyte leakage will occur. For example, FIGS. 25A and 25B show the same battery cell under different internal stresses. In the battery cell, the cathode case member has a bent portion 172.
Although the anode case member has a shape having the rim 174, the battery case may expand when a high internal stress is applied. When the case member starts to separate due to the rise in internal stress,
As the rim 174 of the anode case member continues to act on the edge 176 of the cathode case member, the side walls of the cathode case member will extend outward. This outward spreading causes the battery cells to expand and the electrolyte to leak.

Referring now to FIGS. 26, 26A and 26B, in another embodiment, the case members 102, 104 have a first bend 168 of approximately 180 degrees in the example and approximately 9 degrees.
Strict bend features, including a zero degree second bend 170, maintain mutual engagement. An advantage of this double bend feature is that it substantially eliminates or eliminates the deleterious effects of springback. Unlike the bend 154 in the embodiment of FIG. 8, the slight ductility restoration of one of the two bends 168, 170 causes the cathode case member 104 to act on the peripheral rim 140 of the anode case member 102 via the grommet 130. Is hardly reduced. In the embodiment of FIG. 8A,
At the same time that the bend 154 is formed, the grommet 130 is stressed. Bending part 1
If any springback of 54 is not absorbed by the elasticity of grommet 130, electrolyte leakage may occur. In the present embodiment, the small springback of the bends 168, 170 has little detrimental effect on the battery cell seal, as the bend distance measured relative to the contact point near the bend is little changed. . The possibility of electrolyte leakage through the gap between the case members is substantially reduced.

This embodiment has the advantages described above because the peripheral movement due to restoring ductility does not include a vertical movement in the engagement surface. 1st at small angle φ
Restoring the ductility of the bend 168 has little effect on the distance between the static vertical position line 102A and the engagement surface 170. That is, the first bent portion 168 can be restored from the position 168A to the position 168B without substantially affecting the cell structure.

The second bend 170 should be formed before the first bend 168 to form a double bend feature. Also, the trough 142 of the anode case member 102 should be shaped to leave space for the cathode case member 104 during the formation of the curve 168. Although not shown, the portion of the case member 104 above the second bent portion 170 can be shortened or entirely removed.

According to FIG. 27, in another embodiment, the cathode case member 104 is bent at substantially 90 degrees. While this embodiment lacks some of the benefits of the bends in the embodiments of FIGS. 8A and 26, this embodiment is best suited for battery cells 100 where the internal stress does not rise high or external forces are not applied. This embodiment is easy and inexpensive to manufacture and also provides resistance to the forces separating the case members. The case members 102 and 104 are bent by approximately 90 degrees,
In addition, separation is prevented by an adhesive that fixes the grommet 130 to the case members 102 and 104.

Returning to FIG. 8A, the grommet 130 fills the gap between the case members 102 and 104, the battery cell 100 is sealed, and the electrolyte does not leak. Grommet 130
Is coated with a liquid or semi-liquid sealant to fill the gap between the grommet 130 and the painting walls 114, 116, and to the side walls 114, 1
Sealing is further improved by blocking the small channels of the case members 102, 104 which cause 16 surface flaws. Tar has proven to be a particularly suitable substrate. This substrate is preferably an electrically insulating substrate so that a short circuit does not occur.

Referring to FIGS. 28 and 29, which show another embodiment, the shape of the case members 102, 104 forms an area where the interaction force between the case members 102, 104 is more concentrated, thereby forming the grommet. Improve the sealing performance of 130. In FIG. 28, the radius of the curve 154 is larger than the radius of the rim 140, and the axial force is concentrated substantially at the position 160. In FIG. 29, small peripheral ridges or protrusions have the same effect. Although not shown, the seal can be improved by the addition of small peripheral ridges or protrusions on the surface of grommet 130.

When the electrolyte continues to act on the grommet 130, the
62 is able to absorb the escape of the electrolyte before it fully acts on the battery cell 100. The diaper link 162 is preferably provided between the peripheral trough 142 of the anode case member 102 and the bent portion 154 or the edge 120 of the cathode case member 104.

Returning to the conventional example shown in FIG. 5, which is a partially enlarged cross-sectional view of the conventional example of FIG. 4, the air cathode 64 is disposed near the base 48 of the cathode case member 42, and the air cathode 64 is The oxygen is accessed through an air hole (not shown) drilled in the tub. A hidden Tenryu collector (not shown) is mounted on the air cathode 61,
It provides a means for the charge to flow. The collector edge 66 is exposed and connected to the cathode case member 42, thereby connecting the air cathode 64 to the cathode case member 4.
2 is electrically connected.

In the conventional example, rounded corners of the cathode case member 42 are shown.
Battery cells with rounded internal corners are not reliable. When the air cathode 64 is located at the bottom of the cathode case member 42, the rounded corner 50
Applies a force to an air cathode 64 equipped with a cathode source flow collector (not shown) to bend and conform to the shape of the rounded corner 50. Since the current collector edge 66 is a means of electrically connecting the air cathode 64 to the cathode case member 42, the bend may cause electrical disconnection of the battery cell 40. Preferably, the edge 66 is directly connected to the cathode case member 42, or even more preferably it is bite.

The patent application entitled “Metal-Air Cathode Vessel with Reduced Corner Radius and Electrochemical Cell Using It” and US Pat. No. 5,662,717 disclose a cathode case member having relatively sharp internal corners. are doing. The benefits sought for sharp corners are related to structural improvements, and another benefit is increased reliability. The edges of the cathode current collector bite into sharp corners and are connected. However, sharp interior corners also have disadvantages. Sharp interior corners are difficult or costly to manufacture. Relatively sharp molds are required to form sharp internal corners,
Sharp molds tend to drop quickly. Constant sharpness and replacement are required.

Now, in FIGS. 30A and 30B, which show partial cross sections of the embodiment of FIG. 8A, the cathode case member 104 is characterized in that the reliability is improved and the cost is reduced. The edge of the air cathode 124 and the separator 126 press against the side wall 116 of the cathode case member 104, thereby maintaining an electrical connection between the cathode case member 104 and a concealed current collector 125 mounted on the air cathode 124. Is ensured. Side wall 116 is air cathode 12
4 and preferably substantially perpendicular to the cathode current collector 125.
Since only the edges of the current collector 125 are exposed, a sub-vertical angle of connection may result in the air cathode 124 being electrically disconnected from the case member 104. A substantially vertical connection can be ensured by the shapes and dimensions of the pot structure 134 and the shelf 132. Unlike the prior art example described above and shown in FIG. 5, this embodiment eliminates the possibility that the air cathode 124 will bend and conform to the shape of the rounded inner corner. In addition, this embodiment eliminates the need for sharp corners, which are costly due to frequent replacements and the shape of the mold used to form the sharp corners.

Another feature of the present invention relates to the size and shape of air cathode 124 and separator 126. The regional dimensions of the air cathode 124 and the separator 126 are slightly larger than the regional dimensions that the component would occupy. This slightly larger dimension ensures that the edge of the component is pressed against the side wall 116, thereby ensuring a tight seal with the separator 126 and ensuring an electrical connection with the current collector 125.

However, if the components are too large, the components may become wavy when the battery cell 100 is assembled. One solution is to size the air cathode 124 such that one of the two regional sizes is larger than the occupied size. FIG. 30C shows the dimensional relationship between the surface area of the air cathode 124 before assembly, indicated by reference numeral 175, and the surface area, indicated by reference numeral 177, of the area that the air cathode 124 is or will occupy. The differences are exaggerated.
The length L175 and width W175 of the display 175 before assembly are shorter than the occupied length L177 and width W177, respectively. These dimensional differences ensure that at least two edges of current collector 125 are connected to cathode case member 104 and that air cathode 124
Reduces the likelihood of wave depression. If both the length L175 and the width W175 of the display 175 before assembly are larger than the corresponding dimensions of the occupied display 177, the air cathode 1
24 has a waviness especially at its corner 179.

If the length L 177 of the occupied display 177 is longer than its width W 177, the length L 175 of the display before assembly is preferably longer than the length L 177 of the occupied display 177. The converse is also true. In other words, due to the size of a particular area being longer than two area dimensions, it is (although not necessary) that the air cathode 124 has an area dimension that is longer than the corresponding area size of the occupied display. preferable. It has been found that this structure makes it possible to form an excellent electrical connection while reducing the influence of waviness.

FIG. 31 is an exaggerated representation of another embodiment extending from the cover 195 of the corner area 191 of the display 193 of the surface area of the current collector 127 and the display area occupied by the vacant cathode 124 before assembly. ing. These corners of the current collector 127 are means for connecting the current collector 127 to the case member 104.

In FIG. 30A and FIG. 30B, another characteristic of the pot structure 114 is the separator 12
6 that can be used to capture the electrolyte or adhesive that continues to act on. Although not shown, a peripheral diaper ring similar to the above-described diaper ring 162 can be placed in the recess of the pot structure 134 before leaking through the air access holes 138 of the cathode case member 104. Absorb the electrolyte or adhesive.

32 and 33 showing another embodiment, one of the area dimensions of the air cathode 124 and the separator 126 is larger than the corresponding area size of the occupied area. The air cathode 124 and the separator 12 before being inserted into the cathode case member 104
In FIG. 32 showing 6 and the cathode case member 104, the centers of the parts 124 and 125 are bent away from the base 1212, and smoothly curved to form a facing concave surface. After the cathode case member 104 is inserted, as shown in FIG. 33, the components 124 and 126 are flattened and the vicinity of the edge is bent. Part 124
, 126 ensure that separator 126 is sufficiently sealed and cathode current collector 125 is electrically connected to case member 104.

According to FIG. 34, in another embodiment, the strap 166 is
Resists any deformation and expansion of zero. The strap 166 is connected to the battery cell 1
Snap fit over 00. The strap 166 is preferably made of an elastic material that is insulated so that the strap 166 does not cause a short circuit of the battery cell 100. Although not shown, the case member can include a shape to which the strap 166 fits, and the strap 166 is at least partially mounted on the cathode and anode case members 104, 102. The recess is a strap 166
Is maintained in that position, and the battery cell 100 is easily connected to the electrical device. Also, due to the structure of the battery cell 100, the strap 166 eliminates the need to bend the cathode case member 104.

Referring to FIGS. 35-38, in another embodiment, an asymmetric metal-air battery cell 200 includes two cathodes 2 disposed on opposite ends of a metal anode 202.
01. On the two cathodes are a diffuser 203 and two metal cathode case members 204 having air holes 205. Anode current collector 20
6 is at least partially mounted on a metal anode 202, which is connected to an electrical lead 207. A pair of cathode current collectors (not shown) are provided in the pair of air cathodes 201, and electrically connect the pair of air cathodes 31 to the cathode case member 204.

The grommet 208 firmly surrounds the electric lead 207, thereby preventing the electrolyte from leaking from the battery cell 200 through the hole through which the lead 207 passes. The grommet 208 presses the air cathode 201 into the corresponding cathode case member 204. Although not shown, the electric REIT 207 can also be molded into the grommet 208 or the grommet 208 can be fitted and filled to form a seal. The grommet 20 should be made of an elastic material so that the stress force of the grommet 208 can seal the two cathode case members 204 together. A suitable material for grommet 208 is polysulfone.

A pair of semi-rigid straps 209 hold the contents of the battery cell 200 by a snap fit at location 210. This rigid strap 209 presses the two cathode case members 204 together, which presses against the two air cathodes 201 to compress the grommet 208. Although not shown, the cathode case member 204 can be directly bonded instead of the grommet 208. The use of two air cathodes 201 and one anode 202 allows the battery cell 20
Zero power increases. Both cathodes 201 maintain the same normal voltage with respect to ground, but are similar in one case, increasing air access through the two cathode case members 204,
As the surface area of the two cathodes 201 increases, the amount of current generated in the battery cell 200 increases.

According to FIG. 39, in another embodiment, when the two straps 211 are snap-fitted onto the cathode case member, the straps 211 substantially surround the periphery of the battery cell.

It will be apparent to those skilled in the art that the present invention is not limited to the above description of the embodiments, and that the present invention may be modified without departing from the spirit and essence thereof. Therefore,
It is to be understood that the invention includes modifications, improvements and equivalents within the scope intended by the claims.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view showing a button-shaped cell representing a vector of a force existing when an internal stress becomes higher than the surroundings.

FIG. 2 is a view showing a different cross section of a button-shaped battery cell.

FIG. 3 is a cross-sectional view showing a prism-shaped battery cell in which internal stress is higher than that of the surroundings.

FIG. 4 is a sectional view showing a conventional example of a button-shaped metal-air battery cell.

FIG. 5 is an enlarged partial cross-sectional view of the example of FIG. 4;

FIG. 6 is a cross-sectional view showing the example of FIG. 4 in which the side wall is crushed.

FIG. 7 is a partial cross-sectional view showing one example of a conventional example.

FIG. 8A is a cross-sectional view illustrating a prism-shaped battery cell according to an embodiment of the present invention.

FIG. 8B shows a different cross section of the embodiment of FIG. 8A.

FIG. 9 is a cross-sectional view showing an uncurved cathode case member according to one embodiment of the present invention.

FIG. 10 is a perspective view showing the non-curved cathode case member of FIG. 9;

FIG. 11 is a perspective view showing a part of the cathode case member under a bending moment.

FIG. 12A is a perspective view showing an uncurved cathode case member according to another embodiment of the present invention.

FIG. 12B is a perspective view showing another non-curved cathode case member according to another embodiment of the present invention.

FIG. 12C is a cross-sectional view illustrating a battery cell assembly according to another embodiment of the present invention.

FIGS. 12D and 12D are two enlarged partial cross-sectional views of one embodiment of the present invention.

FIG. 13 is a sectional view showing the anode case member of the embodiment of FIG.

FIG. 14 is an enlarged partial cross-sectional view showing an edge of an anode case member according to another embodiment of the present invention.

FIG. 15 is an enlarged partial cross-sectional view showing an edge of an anode case member according to another embodiment of the present invention.

FIG. 16 is an enlarged partial sectional view showing an edge of an anode case member according to another embodiment of the present invention.

FIG. 17 is an enlarged partial cross-sectional view showing an edge of an anode case member according to another embodiment of the present invention.

FIG. 18 is an enlarged partial cross-sectional view showing an edge of an anode case member according to another embodiment of the present invention.

FIG. 19 is a cross-sectional view showing a bulge or waving of a base of a case member according to another embodiment of the present invention.

FIG. 20 is a cross-sectional view showing a bulge or waving of a base of a case member according to another embodiment of the present invention.

FIG. 21 is a cross-sectional view showing a bulge or waving of a base of a case member according to another embodiment of the present invention.

FIG. 22 is a perspective view showing an anode case member provided with a ridge on an inner surface according to the present invention.

FIG. 22A is a perspective view showing a Teflon (registered trademark) ring related to the embodiment of the present invention.

FIG. 23 is a view showing the peripheral rim of the cathode case member curved around the peripheral rim of the anode case member together with a vector indicating the internal stress thereof.

FIG. 24 is a diagram showing the vector force of the peripheral rim of FIG. 23.

FIG. 25A is a partial cross-sectional view showing one embodiment, schematically showing the necessity of an engagement bending portion of an outer case member in order to correspond to the shape of the inner case member.

FIG. 25B is a partial cross-sectional view showing one embodiment, schematically showing the necessity of an engagement bending portion of the outer case member in order to correspond to the shape of the inner case member.

FIG. 26 is a cross-sectional view showing another embodiment in which double bending is performed to reduce the effect of springback.

FIG. 26A is an enlarged partial sectional view showing the embodiment of FIG. 26 according to the present invention.

FIG. 26B is an enlarged partial sectional view showing the embodiment of FIG. 26 according to the present invention.

FIG. 27 is a partial sectional view showing still another embodiment of the present invention.

FIG. 28 is a partial cross-sectional view illustrating another embodiment of the present invention designed to increase stress in a region to limit electrolyte leakage.

FIG. 29 is a partial cross-sectional view illustrating another embodiment of the present invention designed to increase stress in a region to limit electrolyte leakage.

FIG. 30A is two enlarged cross-sectional views of the embodiment of FIG. 8;

FIG. 30B is two enlarged cross-sectional views of the embodiment of FIG. 8;

FIG. 30C is a cross-sectional view illustrating an air cathode according to one embodiment of the present invention.

FIG. 31 is a cross-sectional view illustrating an air cathode according to another embodiment of the present invention.

FIG. 32 illustrates another embodiment of the present invention, which includes an internal component in which the area of the internal component is slightly larger than the area it is designed to occupy. It is sectional drawing which shows the cathode case member which is not yet curved.

FIG. 33 is a partial sectional view showing the embodiment of FIG. 32 after assembly.

FIG. 34 is a cross-sectional view of another embodiment of the present invention utilizing a snap-fit strap to maintain the case members engaged.

FIG. 35 is a partial sectional view and a whole sectional view showing another embodiment of the present invention using two cathodes to generate a current.

FIG. 36 is a partial sectional view and an entire sectional view showing another embodiment of the present invention using two cathodes to generate a current.

FIG. 37 is a partial sectional view and an entire sectional view showing another embodiment of the present invention using two cathodes to generate a current.

FIG. 38 is a partial sectional view and an entire sectional view showing another embodiment of the present invention using two cathodes to generate a current.

FIG. 39 is a cross-sectional view showing an embodiment similar to the embodiment of FIGS. 35-38 according to the present invention.

──────────────────────────────────────────────────続 き Continuation of front page (81) Designated country EP (AT, BE, CH, CY, DE, DK, ES, FI, FR, GB, GR, IE, IT, LU, MC, NL, PT, SE ), OA (BF, BJ, CF, CG, CI, CM, GA, GN, GW, ML, MR, NE, SN, TD, TG), AP (GH, GM, KE, LS, MW, SD, SL, SZ, TZ, UG, ZW), EA (AM, AZ, BY, KG, KZ, MD, RU, TJ, TM), AE, AL, AM, AT, AU, AZ, BA, BB, BG, BR, BY, CA, CH, CN, CR, CU, CZ, DE, DK, DM, EE, ES, FI, GB, GD, GE, GH, GM, HR, HU, ID , IL, IN, IS, JP, KE, KG, KP, KR, KZ, LC, LK, LR, LS, LT, LU, LV, MA, MD, MG, MK, MN, MW, MX, NO, NZ, PL, PT, RO, RU, SD, SE, SG, SI, SK, SL, TJ, TM, TR, TT, TZ, UA, UG, US, UZ, VN, YU, ZA, ZW (72 Inventor Robert B. Dopp United States 30068 Fields Pond Glen 1925 Marietta, Georgia F-term (reference) 5H011 AA01 AA04 AA17 CC06 CC10 DD06 GG05 HH11 JJ02 KK03 5H032 AA01 AS03 CC01 CC04

Claims (47)

[Claims] 1. A leak-proof case for an electrochemical cell, comprising: at least two case members; wherein the case members are interconnected to form a prism-shaped enclosure; A seal member is disposed between the members; the engagement between the case members is adapted to create a stress on the seal member, which is resisted by at least one of the case members, Forming a seal between said at least one and said sealing member; and said seal limiting the periphery of said enclosure and sealing the contents of said enclosure from the outside world. Case. 2. The method according to claim 1, wherein the engagement is caused by a bend in the first member of the at least two case members, the bend over a corresponding shape of the second member of the at least two case members. The case according to claim 1, wherein 3. The case according to claim 2, wherein the bent portion is at least 90 degrees. 4. Each of said at least two case members has a substantially flat main wall having a side wall, said side wall being continuous with said main wall at an adjacent bend defining said main wall; Contiguous with one continuous peripheral edge; and the periphery of the adjacent bend of the second member of the at least two case members is greater than the periphery of the bend of the peripheral edge of the second member of the at least two case members. 3. The case according to claim 2, wherein the size is also smaller. 5. The at least two case members each having a substantially flat main wall having a side wall, the side wall being continuous with the main wall at an adjacent bend defining the main wall; A second member of the two case members has a substantially flat wall with side walls; the side walls of the case member extend outwardly from the adjacent bend toward the peripheral edge and have a tolerance angle of 90 degrees or more; The case according to claim 2, wherein the case is formed. 6. A leak-resistant case for an electrochemical cell comprising at least two case members, each having a flat main wall; said case members being interconnected to form a prism. Forming an enclosure of a shape; a seal member disposed between the case members; wherein engagement between the case members is adapted to form a sealing stress on the seal member, wherein at least one of the case members is formed. Resisted by one, forming a seal between the at least one of the case members and the seal member; and the seal stress is formed by a substantially axial force, wherein the axial direction is formed by the flat main wall. In contrast, the case characterized by being normal. 7. The case of claim 6, wherein said force is induced by an engagement stress caused by said engagement. 8. The case member according to claim 7, wherein said engaging stress is caused by bending of said first member of said case member so as to cover a correspondingly shaped portion of said second member of said case member. The case described. 9. The case according to claim 8, wherein said engagement stress bending portion is at least 90 degrees. 10. Each of said at least two case members has a substantially flat main wall having a side wall, said side wall being continuous with said main wall at an adjacent bend defining said main wall; Contiguous with one continuous peripheral edge; and wherein the periphery of the adjacent bend of the second member of the at least two case members is the bend of the peripheral edge of the second member of the at least two case members. 9. The case according to claim 8, wherein the case is smaller than the periphery. 11. The wall member wherein each of the at least two case members has a substantially planar main wall having a side wall, the side wall being continuous with the main wall at an adjacent bend defining the main wall; Are continuous so as to define one continuous peripheral edge; and wherein the side wall of the second member of the case member is directed from the adjacent bent portion to the peripheral edge of the second member of the case member. 9. An outwardly extending, crossing angle of at least 90 degrees with the flat wall of the second member of the case member.
The case described. 12. The case according to claim 11, wherein the engagement stress bending portion is at least 90 degrees. 13. The case member has a shape in which the adjacent bent portion of the first member forms a recess; and the engaging stress bending portion is a part of the engaging stress bending portion. 13. The case according to claim 12, wherein said case is shaped to engage said recess. 14. A leak-proof case for an electrochemical cell, comprising: a first and second dish-shaped case member, each having a flat main wall having a side wall; The side wall is continuous with the main wall at an adjacent bent portion defining the main wall, and the side wall has a flat portion and a curved portion continuous with the flat portion; The second case member is inserted into the second case member to form a prism-shaped envelope; the remote portion of the side wall of the second case member is curved beyond the adjacent bent portion of the first case member, and The close bend is shaped such that the distant portion resists the axial force of the first case member, whereby the first and second case members A stress is formed between them; the direction of said axial force The main wall is substantially vertical, and the case where the stress is characterized in that no to seal the first and second casing members. 15. The case of claim 14, wherein at least one adjacent bend in the case member is shaped to increase the at least one stiffness of the case member along its longitudinal axis. . 16. The case according to claim 15, wherein at least one cross section of the adjacent bent portion of the case member is at least two bent portions in opposite directions. 17. The at least one main wall of the case member has a shape having at least one ripple (ripple), whereby the waviness increases the rigidity of the at least one main wall of the case member. 16. The case of claim 15, wherein the case is enhanced. 18. The method of claim 14, wherein the at least one of the adjacent bends of the case member is shaped to disperse a force applied to the adjacent bend of the case member to the corner. Case. 19. The proximal bend of the case member has an engaging portion that resists substantially all of the axial force from a distant portion of the second case member; 15. The case according to claim 14, wherein the formed curvature is shaped such that the minimum extent of the curvature does not substantially change between the engagement portion and the main wall of the second case member. . 20. The case according to claim 19, wherein said at least one of said adjacent bends is at least two bends in opposite directions. 21. The case according to claim 14, further comprising a seal member disposed between said first and second case members. 22. The case of claim 21, wherein said seal member is under stress, and wherein the elasticity of said seal member forms a continuous drag due to said stress. 23. The proximal bend of the first case member has an engagement portion that resists substantially all of the axial force from a distant portion of the second case member;
And the curvature formed at the distant portion is shaped such that the minimum extent of the curvature does not substantially change between the engagement portion and the main wall of the second case member. The case according to claim 21. 24. The case of claim 23, wherein said curvature is at least one bend of approximately 180 degrees. 25. The case of claim 24, wherein the curvature is at least one other bend, and the at least one other direction is a direction opposite to the direction of the at least one bend. 26. The proximity bending portion of the first case member is a recess; and the curvature is shaped to deflect toward the recess when the case member is separated. A case according to claim 24. 27. The curvature formed by the spaced apart portions is greater than or equal to about 90 degrees; and the stress corresponds to a region that substantially defines the curvature, and the non-axial force created by the stress is at least vertical. 15. The case according to claim 14, wherein the case is at least partially canceled in different directions. 28. The non-axial force is substantially canceled.
The case described. 29. A curved portion formed by the distant portion is substantially 90 degrees or more, and one of the side walls of the second case member is connected to the main wall of the second case member by the second. 15. The case according to claim 14, wherein a force that tends to bend in a direction to straighten an adjacent bent portion of the case member is limited. 30. The at least one main wall of the case member has a shape having at least one waviness, whereby the waviness increases the rigidity of the at least one main wall of the case member. Item 14. The case according to Item 14. 31. The at least one undulation disperses substantially a portion of the external force applied between the ends of the at least one undulation to adjacent bending portions of the corresponding case member. Case. 32. The first case member has at least one interior wall connected to at least two different portions of the side wall, the at least one interior wall increasing the stiffness of the first case member. The case according to claim 14, wherein the case is configured as follows. 33. A method of forming a case for a prism-shaped electrochemical cell, comprising: a main wall portion connected to the main wall with a continuous adjacent bend connected at a rounded corner; A first step of forming a second case member having two skirts, wherein the skirt has one continuous edge away from the main wall; at least one of the main walls A second step of further processing the first case member with one and the shape of the skirt such that the edges extend closer to the main wall than at the corners than between the corners; and A third step of forming the enclosure by engaging the first case member with the second case member. 34. The method according to claim 33, wherein the second step is performed in a separating operation. 35. The method according to claim 33, wherein the first step is performed by performing a stamping operation on a sheet of ductile material. 36. The method of claim 33, wherein said one continuous edge in said first step forms a substantially flat protrusion parallel to said main wall portion. 37. The one skirt forms a continuous new edge remote from the main wall; the newly formed edge may form a substantially flat protrusion parallel to the main wall. 34. The forming method according to claim 33, further comprising a step of cutting the main wall after the first step. 38. The method according to claim 33, wherein the second step is performed by a stamping operation using a mold having a protrusion, wherein the protrusion has a shape extending the edge to the main wall portion. 39. A method of assembling a case for a prism-shaped electrochemical cell, comprising: a first step of disposing a substantially flat electrode in a first case member;
Case member has a main wall and side walls joined at rounded corners to form a skirt, the skirt being connected to the main wall with a continuous adjacent bend, the flat protrusions of the side walls being The first step of being connected to the flat projection of the main wall at an obtuse angle; the second step of connecting the first case member to the second case member to form an enclosure; and A third step of bending the first case member so that the angle becomes smaller. 40. The method of claim 39, wherein said first step includes moving said electrode toward an installation location without its edges rubbing against said side walls. 41. The bent portion reduces the angle to 90 degrees or less.
An assembly method according to claim 9, 42. The method according to claim 42, wherein the third bending step increases an interaction force between the electrode and the sidewall such that an electrical connection between the electrode and the sidewall is increased. 40. The method of claim 39 comprising: 43. A kit for making a leak-resistant case for an electrochemical cell, comprising: first and second dish-shaped case members, each having a side wall. Wherein the side wall is continuous with the main wall at an adjacent bend defining the main wall; the side walls of the first and second case members extend continuously to form the one continuous peripheral edge The first case member is inserted into the second case member to form a prism-shaped enclosure; the side wall of the first case member forms a conical portion; The kit wherein the side wall approaches the main wall at the bent portion closer to the periphery than the peripheral edge. 44. The kit of claim 43, wherein said first case member is shaped such that said side wall is bent from an obtuse angle to an acute angle with respect to said main wall. 45. A leak-resistant case for an electrochemical cell comprising: first and second dish-shaped case members, each having a flat main wall having a side wall; Is continuous with the main wall at a close bend defining the main wall; the side walls of the first and second case members extend continuously and are continuous with corners defining the one continuous peripheral edge The first case member is inserted into the second case member to form a prism-shaped enclosure; the first case member is configured to receive an axial force applied to the first case; The side wall of the first case member extends away from the adjacent bend of the first case and engages the side wall of the second case member, thereby supporting the force in the first and second cases. Given by the side wall of the case member Case, characterized in that it forms a so that shape. 46. The peripheral edge of the side wall of the first case member is bent at an angle from the remainder of the side wall, and the peripheral edge of the side wall of the first case member is applied by the force. 46. The case of claim 45, wherein the edge is at an angle to help exert a force into the side wall of the second case member. 47. The case according to claim 46, wherein said angle is approximately 90 degrees.