US20020034680A1 - Battery - Google Patents
Battery Download PDFInfo
- Publication number
- US20020034680A1 US20020034680A1 US09/384,283 US38428399A US2002034680A1 US 20020034680 A1 US20020034680 A1 US 20020034680A1 US 38428399 A US38428399 A US 38428399A US 2002034680 A1 US2002034680 A1 US 2002034680A1
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- US
- United States
- Prior art keywords
- external case
- battery
- recited
- projection
- electrode assembly
- Prior art date
- Legal status (The legal status 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 status listed.)
- Granted
Links
- 239000011248 coating agent Substances 0.000 claims description 16
- 238000000576 coating method Methods 0.000 claims description 16
- 229910052751 metal Inorganic materials 0.000 claims description 5
- 239000002184 metal Substances 0.000 claims description 5
- 238000005520 cutting process Methods 0.000 claims description 2
- 238000007789 sealing Methods 0.000 description 12
- 238000000034 method Methods 0.000 description 9
- 238000004519 manufacturing process Methods 0.000 description 6
- 238000003466 welding Methods 0.000 description 6
- OJIJEKBXJYRIBZ-UHFFFAOYSA-N cadmium nickel Chemical compound [Ni].[Cd] OJIJEKBXJYRIBZ-UHFFFAOYSA-N 0.000 description 5
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 3
- 238000003780 insertion Methods 0.000 description 3
- 230000037431 insertion Effects 0.000 description 3
- 239000000463 material Substances 0.000 description 3
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 2
- 239000011162 core material Substances 0.000 description 2
- 238000005260 corrosion Methods 0.000 description 2
- 230000007797 corrosion Effects 0.000 description 2
- 239000003792 electrolyte Substances 0.000 description 2
- 238000005516 engineering process Methods 0.000 description 2
- 229910000838 Al alloy Inorganic materials 0.000 description 1
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- 241000870659 Crassula perfoliata var. minor Species 0.000 description 1
- HBBGRARXTFLTSG-UHFFFAOYSA-N Lithium ion Chemical compound [Li+] HBBGRARXTFLTSG-UHFFFAOYSA-N 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- 239000000443 aerosol Substances 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 239000004020 conductor Substances 0.000 description 1
- 238000011109 contamination Methods 0.000 description 1
- 230000003247 decreasing effect Effects 0.000 description 1
- 238000010894 electron beam technology Methods 0.000 description 1
- 238000011156 evaluation Methods 0.000 description 1
- 238000010348 incorporation Methods 0.000 description 1
- 238000007373 indentation Methods 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- 229910001416 lithium ion Inorganic materials 0.000 description 1
- 229910052759 nickel Inorganic materials 0.000 description 1
- 229910000652 nickel hydride Inorganic materials 0.000 description 1
- 238000007747 plating Methods 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- 238000000926 separation method Methods 0.000 description 1
- 230000035939 shock Effects 0.000 description 1
- 239000010935 stainless steel Substances 0.000 description 1
- 229910001220 stainless steel Inorganic materials 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 238000012360 testing method Methods 0.000 description 1
Images
Classifications
-
- 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
- H01M50/10—Primary casings; Jackets or wrappings
- H01M50/172—Arrangements of electric connectors penetrating the casing
- H01M50/174—Arrangements of electric connectors penetrating the casing adapted for the shape of the cells
-
- 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
- H01M50/10—Primary casings; Jackets or wrappings
- H01M50/102—Primary casings; Jackets or wrappings characterised by their shape or physical structure
- H01M50/107—Primary casings; Jackets or wrappings characterised by their shape or physical structure having curved cross-section, e.g. round or elliptic
-
- 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
- H01M50/10—Primary casings; Jackets or wrappings
- H01M50/116—Primary casings; Jackets or wrappings characterised by the material
- H01M50/124—Primary casings; Jackets or wrappings characterised by the material having a layered structure
- H01M50/1245—Primary casings; Jackets or wrappings characterised by the material having a layered structure characterised by the external coating on the casing
-
- 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
- H01M50/50—Current conducting connections for cells or batteries
- H01M50/528—Fixed electrical connections, i.e. not intended for disconnection
-
- 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
- H01M50/50—Current conducting connections for cells or batteries
- H01M50/531—Electrode connections inside a battery casing
- H01M50/533—Electrode connections inside a battery casing characterised by the shape of the leads or tabs
-
- 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
- H01M50/50—Current conducting connections for cells or batteries
- H01M50/531—Electrode connections inside a battery casing
- H01M50/534—Electrode connections inside a battery casing characterised by the material of the leads or tabs
-
- 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
- H01M50/50—Current conducting connections for cells or batteries
- H01M50/571—Methods or arrangements for affording protection against corrosion; Selection of materials therefor
-
- 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
- H01M10/05—Accumulators with non-aqueous electrolyte
- H01M10/052—Li-accumulators
- H01M10/0525—Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodes; Lithium-ion batteries
-
- 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
- H01M10/24—Alkaline accumulators
- H01M10/30—Nickel accumulators
-
- 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
- H01M10/34—Gastight accumulators
- H01M10/345—Gastight metal hydride accumulators
-
- 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
Definitions
- This invention relates to a battery in which a lead (an electrically conducting lead, not the element Pb) plate connected to an electrode assembly is welded to the bottom plate of an external case by an energy beam such as a laser.
- a laminate of positive electrode plate, negative electrode plate, and separator in between, is rolled into a spiral shape to form the electrode assembly.
- the spiral shaped electrode assembly is formed with a center hole to insert an electrode rod for weld connection.
- the electrode assembly is inserted into a circular cylindrical external case with a bottom.
- a lead plate connected to the bottom of the electrode assembly is weld attached to connect it to the bottom of the external case.
- an electrode rod 2 for weld connection is inserted into the electrode assembly 1 center hole, and the lead plate 4 is pushed by the electrode rod 2 against the bottom plate of the external case 5 and welded.
- a lead plate which draws out of the top of the electrode assembly 1 is connected to an electrode on a sealing lid which closes off the opening at the top of the external case 5 .
- the sealing lid is fixed to the opening in the external case.
- the external case is sealed in an airtight fashion by the sealing lid.
- This process has the characteristic that the lead plate 4 connected to the electrode assembly 1 can be reliably welded and fixed to the bottom plate of the external case 5 .
- a battery of this configuration must be provided with a center hole in the middle of the electrode assembly 1 , and this center hole must have a diameter larger than the electrode rod for weld connection. Therefore, the actual volume of the electrode assembly is reduced and the battery's capacity is decreased.
- Increasing battery capacity by reducing the size of the electrode assembly center hole may be considered, but when center hole size is reduced, fitting the electrode rod in the center hole becomes a problem.
- the energy beam will also fail to make a reliable weld attachment.
- whether or not the lead plate is weld attached to the bottom plate and what kind of attachment is made cannot be determined from outside this type of battery. Since evaluation of battery quality is difficult, it is extremely important to make weld attachments more reliably.
- This invention was developed to solve these types of problems. It is thus a primary object of the present invention to provide a battery that can reliably weld attach a lead plate to an external case.
- the battery has an electrode assembly inserted into a cylindrical external case.
- a lead plate connected to the electrode assembly is weld attached to inner surface of the external case by an energy beam applied from outside the external case.
- the battery of the present invention is provided with a projection which projects from the inner surface of the external case.
- An energy beam is applied to the projection from outside the external case to weld attach the inner surface of the projection to the lead plate.
- a battery of this configuration has the characteristic that the lead plate can be reliably weld attached to the external case. This is because the projection in the external case makes reliable contact with the lead plate.
- the external case and lead plate can be reliably weld attached by application of an energy beam, such as a laser, to the projection which has its inner surface in contact with the lead plate.
- an energy beam such as a laser
- a battery, in which the lead plate and external case can be reliably contacted and welded also reliably prevents separation of the lead plate and external case due to mechanical shock.
- the projection is disposed in a still more preferable arrangement for contact and weld attachment to the lead plate by curving the projecting surface to its center or by making a conical shaped projection.
- the lead plate of the battery can be provided with a flexible deforming piece, and the projection in the external case can be weld attached to this flexible deforming piece.
- the flexible deforming piece can jut outwards towards the projection in the external case to further improve connection of the lead plate and the external case.
- Anti-corrosive coating can be used to coat the region of the battery where the energy beam is applied from outside the external case. This effectively prevents corrosion of the region of energy beam application, and contact resistance problems can be avoided via the anti-corrosive coating.
- FIG. 1 is a cross section view showing a prior art battery fabrication method.
- FIG. 2 is a cross section view showing another fabrication method of a prior art battery.
- FIG. 3 is a cross section view showing an embodiment of a battery of the present invention.
- FIG. 4 is a cross section view showing the bottom of the external case of the battery shown in FIG. 3.
- FIG. 5 is a cross section view showing the bottom of the external case of a battery of another embodiment of the present invention.
- FIG. 6 is a bottom view of the external case shown in FIG. 4.
- FIG. 7 is a cross section view showing the bottom region of a battery of another embodiment of the present invention.
- FIG. 8 is a plan view showing the lead plate contained at the bottom of the battery shown in FIG. 3.
- FIG. 9 is a plan view showing the lead plate contained at the top of the battery shown in FIG. 3.
- FIG. 10 is an enlarged cross section view of a lead plate.
- FIG. 11 is a cross section view showing the disposition of a lead plate for weld attachment to an electrode assembly.
- FIG. 12 is a front view showing another type of lead plate for incorporation into a battery of the present invention.
- the battery shown in FIG. 3 is a rechargeable battery such as a nickel hydride battery, a nickel cadmium battery, or a lithium ion battery, and is provided with a circular cylindrical external case 35 , an electrode assembly 31 for insertion into this external case 35 , and lead plates 33 , 34 for connecting the electrode assembly 31 to the external case 35 .
- the external case of the battery shown in FIG. 3 has a circular cylindrical shape
- the external case of the battery of the present invention is not limited to a circular cylindrical shape.
- the external case may also take on, for example, a rectangular cylindrical shape or an elliptical cylindrical shape.
- the external case 35 is made of iron or steel with nickel plated surfaces.
- the material for the external case 35 is the optimum metal selected considering the type of battery and its characteristics.
- the external case 35 may also be made of stainless steel, aluminum, or aluminum alloy.
- the open region at the upper end of the metal external case 35 is sealed closed in an airtight fashion by the sealing lid 37 .
- the sealing lid 37 of FIG. 3 is fixed in place on the external case 35 in an electrically insulating fashion by a caulked junction structure.
- the sealing lid may also be fixed on the external case in an airtight fashion by a method such as laser welding. This configuration of sealing lid insulates and holds an electrode stationary.
- the sealing lid 37 fixes one terminal of the battery in place.
- the external case 35 is provided with a projection 35 a in the region where the lead plate 34 is welded and fixed to the external case 35 .
- a projection 35 a is provided on the bottom plate 35 A of the external case 35 of the battery shown in the figures, and the lead plate 34 is weld attached to this projection 35 a .
- the external case 35 is provided with a projection 35 a at the center of the bottom plate 35 A.
- An external case 35 provided with a projection 35 a in this location has the characteristic that the location for weld attachment of the lead plate 34 by an energy beam operation such as laser welding can be easily and accurately aligned.
- the location for energy beam weld attachment of the lead plate 34 does not change regardless of the position to which the external case 35 has rotated.
- the projection is not required to be provided on the bottom plate.
- the projection may also be provided on a side-wall of the external case 75 .
- the lead plate 74 is weld attached to the projection 75 a.
- the outside diameter of the projection 35 a is designed to an optimum value considering the area of the weld attach. If the diameter of the projection 35 a is made small, the top of the projection can be reliably weld attached to the lead plate. However, if the projection diameter is too small, the weld attach area between the lead plate and external case becomes smaller.
- the projection 35 a is shaped with its convex surface curved around the central protrusion. Or, as shown in FIG. 5, the projection 55 a protrudes outward in a conical shape.
- the lead plate 54 contacts the projection 55 a without gaps or voids. Therefore, a battery of this type has the characteristic that the lead plate 54 and projection 55 a can be more reliably weld attached.
- the protruding surface of the projection 55 a may also be planar.
- the electrode assembly 31 is a laminate of a positive electrode plate, a negative electrode plate, and a separator in between.
- the battery shown in FIG. has a stack of positive electrode plate, negative electrode plate, and intervening separator rolled together.
- This spiral shaped electrode assembly 31 is inserted into the circular cylindrical external case 35 .
- the spiral electrode assembly 31 may also be pressed from both sides to distort it into an elliptical shape for insertion into an elliptical shaped or rectangular shaped external case.
- an electrode assembly for insertion into a square cylindrical external case can also be fabricated by cutting a plurality of positive electrode plate and negative electrode plate sheets, and stacking them with separator in between.
- the electrode assembly 31 has lead plates 33 , 34 connected to the positive and negative electrode plates.
- the lead plates 33 , 34 are disposed at the top and bottom of the electrode assembly 31 and are connected to the positive and negative electrode plates.
- positive and negative electrode plate core material projects upward and downward from the electrode assembly 31 , and the lead plates 33 , 34 are connected to these projections.
- the electrode plate 34 disposed at the bottom of the electrode assembly 31 is connected to the external case 35 .
- the electrode plate 33 disposed at the top of the electrode assembly 31 is connected to the sealing lid 37 .
- the lead plates 33 , 34 which connect to the top and bottom of the electrode assembly 31 , are cut from metal plate in disk shapes smaller than the inside of the external case 35 .
- the lead plate 33 which connects to the top surface of the electrode assembly 31 has a lead strip 33 A projecting from its periphery.
- the lead strip 33 A connects to the sealing lid 37 , which is electrically insulated from, and attaches to the open region of the external case 35 .
- a lead plate 33 of the shape shown in FIG. 9 may also be used to connect the bottom surface of the electrode assembly to a side-wall of the external case.
- these types of lead plates 33 , 34 are pressed against the electrode assembly 31 via a welding electrode 38 , and reliably connected by resistive electric welding.
- a plurality of holes 39 are opened through the lead plates 33 , 34 shown in FIGS. 8 and 9 to reliably connect the lead plates 33 , 34 electrically to the electrodes of the electrode assembly 31 .
- projections 310 are provided extending downward from the periphery of the holes 39 in the lead plates 33 , 34 .
- the projections 310 are connected to the electrode plates of the electrode assembly.
- the lead plate 33 which connects to the top of the electrode assembly 31 , is provided with slits 313 on either side of a center hole 311 to reduce unnecessary electric current during resistive electric welding.
- the lead plate 33 which connects to the top of the electrode assembly 31 , is provided with a U-shaped cut-out 312 , and a flexible deforming piece 34 A is provided inside this cut-out 312 .
- the flexible deforming piece 34 A protrudes outwards towards the projection 35 a in the external case 35 .
- the flexible deforming piece 34 A is approximately at the center of the lead plate 34 , and is weld attached to the external case 35 projection 35 a.
- lead plates 33 , 34 in a battery of this configuration can connect to the electrode assembly 31 at a plurality of locations, the battery has excellent high current characteristics. This is because internal resistance can be made small. Further, a battery of this configuration also has the characteristic that the lead plate 34 can be reliably weld attached to the bottom plate 35 A via an energy beam. This is because the electrode assembly 31 can be inserted into the external case 35 and the lead plate 34 can be put in intimate contact with the bottom plate 35 A of the external case.
- the battery of the present invention is not limited to a lead plate, which connects the electrode assembly to the external case, according to the structure described above.
- the lead plate may also have a band shape as shown in FIG. 12.
- This lead plate 124 connects to exposed core material of an electrode, extends out from the bottom of the electrode assembly, and its end weld attaches to the inner surface of the external case.
- This type of lead plate 124 may also extend out from the side of the electrode assembly and weld attach to a side-wall of the external case as shown in FIG. 7.
- the lead plate 34 is weld attached to the inner surface of the external case 35 .
- An energy beam such as a laser beam or an electron beam, etc. is used as a method of weld attaching the lead plate 34 .
- the energy beam fuses both the external case 35 and the lead plate 34 to weld attach the lead plate 34 and the external case 35 .
- a laser beam is shined at a wide region, which includes the entire projection 35 a , to weld attach the lead plate 34 and the external case 35 .
- the anti-corrosive coating 36 can be sprayed in aerosol form or applied using a paint brush. Further, the anti-corrosive coating 36 may also be sprayed from a miniature nozzle according to ink-jet technology.
- the ink jet method has the characteristic that a precise thickness of anti-corrosive coating can be applied to the precise location of energy beam application.
- the anti-corrosive coating 36 can also be applied at the same time the date of manufacture and the usable date are printed on the external case of the battery by ink-jet.
- Nickel cadmium batteries were fabricated by the following process, and lead plate to external case connections were tested.
- An external case provided with a projection 35 a in the center of the bottom surface, as shown in FIG. 4, was used.
- the projection 35 a was shaped with its convex surface curved around the central protrusion.
- the outside diameter of the projection 35 a was approximately 2 mm, the height of the projection was 0.2 mm, and the radius of curvature of the protruding surface was 15 mm.
- a lead plate 34 which connects to the bottom surface of the electrode assembly 31 , a configuration provided with a flexible deforming piece 34 A, as shown in FIG. 8, was used.
- a flexible deforming piece 34 A which protruded outwards approximately 0.2 mm was used.
- Nickel cadmium batteries were fabricated by the same process as embodiment 1 except the lead plate connected to the bottom surface of the electrode assembly had no flexible deforming piece. The region of the lead plate for weld attachment to the external case was planar for this battery.
- Nickel cadmium batteries were fabricated by the same process as embodiment 1 except the bottom surface of the external case had no projection.
- batteries of embodiment 1 and embodiment 2 had lead plates and external cases reliably connected. In particular, there was no failure of lead plate to external case weld attach for batteries of embodiment 1.
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- Chemical & Material Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Electrochemistry (AREA)
- General Chemical & Material Sciences (AREA)
- Connection Of Batteries Or Terminals (AREA)
- Sealing Battery Cases Or Jackets (AREA)
Abstract
Description
- This application is based on application No.10-245119 filed in Japan on Aug. 31, 1998, the content of which incorporated hereinto by reference.
- This invention relates to a battery in which a lead (an electrically conducting lead, not the element Pb) plate connected to an electrode assembly is welded to the bottom plate of an external case by an energy beam such as a laser.
- The following describes fabrication of a prior art battery in which a lead plate connected to an electrode assembly is welded to the bottom plate of an external case.
- (1) A laminate of positive electrode plate, negative electrode plate, and separator in between, is rolled into a spiral shape to form the electrode assembly. The spiral shaped electrode assembly is formed with a center hole to insert an electrode rod for weld connection.
- (2) The electrode assembly is inserted into a circular cylindrical external case with a bottom.
- (3) A lead plate connected to the bottom of the electrode assembly is weld attached to connect it to the bottom of the external case. As shown in FIG. 1, an
electrode rod 2 for weld connection is inserted into theelectrode assembly 1 center hole, and thelead plate 4 is pushed by theelectrode rod 2 against the bottom plate of the external case 5 and welded. - (4) A lead plate which draws out of the top of the
electrode assembly 1 is connected to an electrode on a sealing lid which closes off the opening at the top of the external case 5. After the external case is filled with electrolyte, the sealing lid is fixed to the opening in the external case. The external case is sealed in an airtight fashion by the sealing lid. - This process has the characteristic that the
lead plate 4 connected to theelectrode assembly 1 can be reliably welded and fixed to the bottom plate of the external case 5. However, a battery of this configuration must be provided with a center hole in the middle of theelectrode assembly 1, and this center hole must have a diameter larger than the electrode rod for weld connection. Therefore, the actual volume of the electrode assembly is reduced and the battery's capacity is decreased. Increasing battery capacity by reducing the size of the electrode assembly center hole may be considered, but when center hole size is reduced, fitting the electrode rod in the center hole becomes a problem. - Technology for connecting a lead plate to the bottom of an external case by laser welding from outside the case has been developed to eliminate the drawbacks of a battery with the configuration described above (Japanese Non-examined Patent Publications No. 4-162351 issued on Jun. 5, 1992 and No. 8-293299 issued on Nov. 5, 1996). These and other disclosures cite batteries which do not use an electrode rod for weld connection. As shown in FIG. 2, an energy beam such as a laser is applied to the
bottom plate 25A of theexternal case 25 from outside the case. The energy beam fuses a portion of thebottom plate 25A and thelead plate 24 to weld and attach thelead plate 24 to thebottom plate 25A. - As shown in FIG. 2, there is no need to provide a center hole in the
electrode assembly 21 of a battery in which an energy beam such as a laser beam is applied from outside the case to weld the lead plate to the bottom plate. Consequently, this type of battery has the characteristic that the actual electrode assembly volume and battery discharge capacity can be increased. However, in this type of battery in which the lead plate is weld attached from outside the external case, the lead plate can fail to reliably weld attached to the bottom plate. For example, with the electrode assembly inserted into the external case, if the lead plate is separated from the bottom plate, the bottom plate of the external case will fuse but the lead plate will not, and the energy beam will not be able to reliably weld attach the lead plate to the bottom plate. In addition, if foreign material or contamination is between the lead plate and bottom plate, the energy beam will also fail to make a reliable weld attachment. In particular, whether or not the lead plate is weld attached to the bottom plate and what kind of attachment is made cannot be determined from outside this type of battery. Since evaluation of battery quality is difficult, it is extremely important to make weld attachments more reliably. - This invention was developed to solve these types of problems. It is thus a primary object of the present invention to provide a battery that can reliably weld attach a lead plate to an external case.
- The above and further objects and features of the invention will more fully be apparent from the following detailed description with accompanying drawings.
- The battery has an electrode assembly inserted into a cylindrical external case. A lead plate connected to the electrode assembly is weld attached to inner surface of the external case by an energy beam applied from outside the external case.
- Further, the battery of the present invention is provided with a projection which projects from the inner surface of the external case. An energy beam is applied to the projection from outside the external case to weld attach the inner surface of the projection to the lead plate.
- A battery of this configuration has the characteristic that the lead plate can be reliably weld attached to the external case. This is because the projection in the external case makes reliable contact with the lead plate. The external case and lead plate can be reliably weld attached by application of an energy beam, such as a laser, to the projection which has its inner surface in contact with the lead plate. In particular, a battery, in which the lead plate and external case can be reliably contacted and welded, also reliably prevents separation of the lead plate and external case due to mechanical shock.
- In the battery of the present invention, the projection is disposed in a still more preferable arrangement for contact and weld attachment to the lead plate by curving the projecting surface to its center or by making a conical shaped projection.
- Further, the lead plate of the battery can be provided with a flexible deforming piece, and the projection in the external case can be weld attached to this flexible deforming piece. In addition, the flexible deforming piece can jut outwards towards the projection in the external case to further improve connection of the lead plate and the external case.
- Anti-corrosive coating can be used to coat the region of the battery where the energy beam is applied from outside the external case. This effectively prevents corrosion of the region of energy beam application, and contact resistance problems can be avoided via the anti-corrosive coating.
- FIG. 1 is a cross section view showing a prior art battery fabrication method.
- FIG. 2 is a cross section view showing another fabrication method of a prior art battery.
- FIG. 3 is a cross section view showing an embodiment of a battery of the present invention.
- FIG. 4 is a cross section view showing the bottom of the external case of the battery shown in FIG. 3.
- FIG. 5 is a cross section view showing the bottom of the external case of a battery of another embodiment of the present invention.
- FIG. 6 is a bottom view of the external case shown in FIG. 4.
- FIG. 7 is a cross section view showing the bottom region of a battery of another embodiment of the present invention.
- FIG. 8 is a plan view showing the lead plate contained at the bottom of the battery shown in FIG. 3.
- FIG. 9 is a plan view showing the lead plate contained at the top of the battery shown in FIG. 3.
- FIG. 10 is an enlarged cross section view of a lead plate.
- FIG. 11 is a cross section view showing the disposition of a lead plate for weld attachment to an electrode assembly.
- FIG. 12 is a front view showing another type of lead plate for incorporation into a battery of the present invention.
- The battery shown in FIG. 3 is a rechargeable battery such as a nickel hydride battery, a nickel cadmium battery, or a lithium ion battery, and is provided with a circular cylindrical
external case 35, anelectrode assembly 31 for insertion into thisexternal case 35, andlead plates electrode assembly 31 to theexternal case 35. Although the external case of the battery shown in FIG. 3 has a circular cylindrical shape, the external case of the battery of the present invention is not limited to a circular cylindrical shape. Although not illustrated, the external case may also take on, for example, a rectangular cylindrical shape or an elliptical cylindrical shape. - The
external case 35 is made of iron or steel with nickel plated surfaces. The material for theexternal case 35 is the optimum metal selected considering the type of battery and its characteristics. For example, theexternal case 35 may also be made of stainless steel, aluminum, or aluminum alloy. The open region at the upper end of the metalexternal case 35 is sealed closed in an airtight fashion by the sealinglid 37. The sealinglid 37 of FIG. 3 is fixed in place on theexternal case 35 in an electrically insulating fashion by a caulked junction structure. The sealing lid may also be fixed on the external case in an airtight fashion by a method such as laser welding. This configuration of sealing lid insulates and holds an electrode stationary. The sealinglid 37 fixes one terminal of the battery in place. - As shown in FIGS. 3 and 4, the
external case 35 is provided with aprojection 35 a in the region where thelead plate 34 is welded and fixed to theexternal case 35. Aprojection 35 a is provided on thebottom plate 35A of theexternal case 35 of the battery shown in the figures, and thelead plate 34 is weld attached to thisprojection 35 a. As shown in the bottom view of FIG. 6, theexternal case 35 is provided with aprojection 35 a at the center of thebottom plate 35A. Anexternal case 35 provided with aprojection 35 a in this location has the characteristic that the location for weld attachment of thelead plate 34 by an energy beam operation such as laser welding can be easily and accurately aligned. This is because the location for energy beam weld attachment of thelead plate 34 does not change regardless of the position to which theexternal case 35 has rotated. However, there is no requirement to locate the projection at the center of the bottom plate. Further, the projection is not required to be provided on the bottom plate. For example, as shown in FIG. 7, the projection may also be provided on a side-wall of theexternal case 75. However, regardless of where the projection is provided, thelead plate 74 is weld attached to theprojection 75 a. - The outside diameter of the
projection 35 a is designed to an optimum value considering the area of the weld attach. If the diameter of theprojection 35 a is made small, the top of the projection can be reliably weld attached to the lead plate. However, if the projection diameter is too small, the weld attach area between the lead plate and external case becomes smaller. - Making the
projection 35 a jut high up from the inner surface of theexternal case 35 improves the situation for weld attachment of theprojection 35 a and thelead plate 34. However, making theprojection 35 a project high upwards pushes theelectrode assembly 31, which inserts into theexternal case 35, upwards. Consequently, this makes it necessary to reduce the height of theelectrode assembly 31, and this reduces the real capacity of the electrode assembly. - As shown in Fig,4, the
projection 35 a is shaped with its convex surface curved around the central protrusion. Or, as shown in FIG. 5, theprojection 55 a protrudes outward in a conical shape. In a battery with a projection having a protruding surface in one of these configurations, thelead plate 54 contacts theprojection 55 a without gaps or voids. Therefore, a battery of this type has the characteristic that thelead plate 54 andprojection 55 a can be more reliably weld attached. However, the protruding surface of theprojection 55 a may also be planar. - The
electrode assembly 31 is a laminate of a positive electrode plate, a negative electrode plate, and a separator in between. The battery shown in FIG. has a stack of positive electrode plate, negative electrode plate, and intervening separator rolled together. This spiral shapedelectrode assembly 31 is inserted into the circular cylindricalexternal case 35. Thespiral electrode assembly 31 may also be pressed from both sides to distort it into an elliptical shape for insertion into an elliptical shaped or rectangular shaped external case. Further, an electrode assembly for insertion into a square cylindrical external case can also be fabricated by cutting a plurality of positive electrode plate and negative electrode plate sheets, and stacking them with separator in between. - The
electrode assembly 31 has leadplates lead plates electrode assembly 31 and are connected to the positive and negative electrode plates. As shown in FIG. 3, positive and negative electrode plate core material projects upward and downward from theelectrode assembly 31, and thelead plates electrode assembly 31 in the figures, theelectrode plate 34 disposed at the bottom of theelectrode assembly 31 is connected to theexternal case 35. Theelectrode plate 33 disposed at the top of theelectrode assembly 31 is connected to the sealinglid 37. - As shown in FIGS. 8 and 9, the
lead plates electrode assembly 31, are cut from metal plate in disk shapes smaller than the inside of theexternal case 35. As shown in FIG. 9, thelead plate 33 which connects to the top surface of theelectrode assembly 31 has alead strip 33A projecting from its periphery. Thelead strip 33A connects to the sealinglid 37, which is electrically insulated from, and attaches to the open region of theexternal case 35. Alead plate 33 of the shape shown in FIG. 9 may also be used to connect the bottom surface of the electrode assembly to a side-wall of the external case. - As shown in the cross section view of FIG. 11, these types of
lead plates electrode assembly 31 via awelding electrode 38, and reliably connected by resistive electric welding. A plurality ofholes 39 are opened through thelead plates lead plates electrode assembly 31. As shown in the enlarged cross section view of FIG. 10,projections 310 are provided extending downward from the periphery of theholes 39 in thelead plates projections 310 are connected to the electrode plates of the electrode assembly. Further, as shown in FIG. 9, thelead plate 33, which connects to the top of theelectrode assembly 31, is provided withslits 313 on either side of acenter hole 311 to reduce unnecessary electric current during resistive electric welding. - As shown in FIG. 8, the
lead plate 33, which connects to the top of theelectrode assembly 31, is provided with a U-shaped cut-out 312, and aflexible deforming piece 34A is provided inside this cut-out 312. Theflexible deforming piece 34A protrudes outwards towards theprojection 35 a in theexternal case 35. Theflexible deforming piece 34A is approximately at the center of thelead plate 34, and is weld attached to theexternal case 35projection 35 a. - Since
lead plates electrode assembly 31 at a plurality of locations, the battery has excellent high current characteristics. This is because internal resistance can be made small. Further, a battery of this configuration also has the characteristic that thelead plate 34 can be reliably weld attached to thebottom plate 35A via an energy beam. This is because theelectrode assembly 31 can be inserted into theexternal case 35 and thelead plate 34 can be put in intimate contact with thebottom plate 35A of the external case. - However, the battery of the present invention is not limited to a lead plate, which connects the electrode assembly to the external case, according to the structure described above. For example, the lead plate may also have a band shape as shown in FIG. 12. This
lead plate 124 connects to exposed core material of an electrode, extends out from the bottom of the electrode assembly, and its end weld attaches to the inner surface of the external case. This type oflead plate 124 may also extend out from the side of the electrode assembly and weld attach to a side-wall of the external case as shown in FIG. 7. - The
lead plate 34 is weld attached to the inner surface of theexternal case 35. An energy beam such as a laser beam or an electron beam, etc. is used as a method of weld attaching thelead plate 34. The energy beam fuses both theexternal case 35 and thelead plate 34 to weld attach thelead plate 34 and theexternal case 35. As shown in FIG. 4, a laser beam is shined at a wide region, which includes theentire projection 35 a, to weld attach thelead plate 34 and theexternal case 35. - When an energy beam such as a laser beam is applied to the outer surface of the
external case 35, corrosion resistant metal plating, which coats the surface of theexternal case 35, loses its effectiveness. Consequently, the region of energy beam application can easily corrode. This drawback can be eliminated by coating the region of energy beam application with ananti-corrosive coating 36, as shown in the enlarged portion of the cross section view of FIG. 3. However, whenanti-corrosive coating 36 is applied to the bottom surface of theexternal case 35, theanti-corrosive coating 36 can be the cause of contact resistance during battery operation. This is because non-conducting organic coating material is used as theanti-corrosive coating 36. This drawback can be eliminated by mixing conductive material such as carbon or metallic powder into theanti-corrosive coating 36. - The
anti-corrosive coating 36 can be sprayed in aerosol form or applied using a paint brush. Further, theanti-corrosive coating 36 may also be sprayed from a miniature nozzle according to ink-jet technology. The ink jet method has the characteristic that a precise thickness of anti-corrosive coating can be applied to the precise location of energy beam application. In addition, theanti-corrosive coating 36 can also be applied at the same time the date of manufacture and the usable date are printed on the external case of the battery by ink-jet. - Nickel cadmium batteries were fabricated by the following process, and lead plate to external case connections were tested. An external case provided with a
projection 35 a in the center of the bottom surface, as shown in FIG. 4, was used. Theprojection 35 a was shaped with its convex surface curved around the central protrusion. The outside diameter of theprojection 35 a was approximately 2 mm, the height of the projection was 0.2 mm, and the radius of curvature of the protruding surface was 15 mm. - As a
lead plate 34, which connects to the bottom surface of theelectrode assembly 31, a configuration provided with aflexible deforming piece 34A, as shown in FIG. 8, was used. Aflexible deforming piece 34A, which protruded outwards approximately 0.2 mm was used. - An electrode assembly rolled into a spiral shape with a separator between electrodes and lead
plates external case 35 with the above configuration. Leadplates holes 39 andprojections 310 provided at the periphery of theholes 39 were used. The electrode assembly was inserted into the external case, a laser was applied to the indentation corresponding to theprojection 35 a provided in the bottom surface of the external case, and thelead plate 34 was weld attached to theexternal case 35. As a coating on the laser weld region at the outer bottom surface of the external case, Hitachi Manufacturing LTD. [JP-K28] was applied. After weld attaching thelead plate 33 connected to the top surface of the electrode assembly to the sealinglid 37, electrolyte was added, and the opening in the external case was closed off with the sealinglid 37 to complete fabrication of a nickel cadmium battery. - Nickel cadmium batteries were fabricated by the same process as
embodiment 1 except the lead plate connected to the bottom surface of the electrode assembly had no flexible deforming piece. The region of the lead plate for weld attachment to the external case was planar for this battery. - Nickel cadmium batteries were fabricated by the same process as
embodiment 1 except the bottom surface of the external case had no projection. - The following shows comparison of lead plate to external case weld attach success ratios for batteries fabricated as described above.
Batteries of Embodiment 1100% Batteries of Embodiment 298% Batteries of the Comparison Example 97% - From these test results, batteries of
embodiment 1 andembodiment 2 had lead plates and external cases reliably connected. In particular, there was no failure of lead plate to external case weld attach for batteries ofembodiment 1. - As this invention may be embodied in several forms without departing from the spirit of essential characteristics thereof, the present embodiment is therefore illustrative and not restrictive, since the scope of the invention is defined by the appended claims rather than by the description preceding them, and all changes that fall within the meets and bounds of the claims or equivalence of such meets and bounds thereof are therefore intended to be embraced by the claims.
Claims (15)
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP245119/1998 | 1998-08-31 | ||
JP10-245119 | 1998-08-31 | ||
JP24511998A JP3738136B2 (en) | 1998-08-31 | 1998-08-31 | battery |
Publications (2)
Publication Number | Publication Date |
---|---|
US20020034680A1 true US20020034680A1 (en) | 2002-03-21 |
US6379839B1 US6379839B1 (en) | 2002-04-30 |
Family
ID=17128913
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US09/384,283 Expired - Lifetime US6379839B1 (en) | 1998-08-31 | 1999-08-27 | Battery having welded lead plate |
Country Status (4)
Country | Link |
---|---|
US (1) | US6379839B1 (en) |
JP (1) | JP3738136B2 (en) |
CN (1) | CN1142604C (en) |
HK (1) | HK1025186A1 (en) |
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Also Published As
Publication number | Publication date |
---|---|
CN1246734A (en) | 2000-03-08 |
JP2000077040A (en) | 2000-03-14 |
HK1025186A1 (en) | 2000-11-03 |
US6379839B1 (en) | 2002-04-30 |
JP3738136B2 (en) | 2006-01-25 |
CN1142604C (en) | 2004-03-17 |
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