WO1994003933A1 - Process for manufacturing an electrochemical cathode with bus bar and products produced thereby - Google Patents

Process for manufacturing an electrochemical cathode with bus bar and products produced thereby Download PDF

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Publication number
WO1994003933A1
WO1994003933A1 PCT/US1993/007089 US9307089W WO9403933A1 WO 1994003933 A1 WO1994003933 A1 WO 1994003933A1 US 9307089 W US9307089 W US 9307089W WO 9403933 A1 WO9403933 A1 WO 9403933A1
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WO
WIPO (PCT)
Prior art keywords
bus bar
strip
cathode
bar material
current
Prior art date
Application number
PCT/US1993/007089
Other languages
French (fr)
Inventor
Bhaskara M. L. Rao
William Kobasz
Robert G. Cook
Original Assignee
Alupower, Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Alupower, Inc. filed Critical Alupower, Inc.
Publication of WO1994003933A1 publication Critical patent/WO1994003933A1/en

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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/86—Inert electrodes with catalytic activity, e.g. for fuel 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
    • H01M50/50—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
    • H01M50/531—Electrode connections inside a battery casing
    • H01M50/536—Electrode connections inside a battery casing characterised by the method of fixing the leads to the electrodes, e.g. by welding
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/10—Energy storage using batteries
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • 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
    • Y02E60/30—Hydrogen technology
    • Y02E60/50—Fuel cells

Definitions

  • This invention relates to a process for manufacturing electrodes and electrodes produced thereby/ and more particularly to a process for manufacturing electrochemical cathodes for use in electrochemical cells and electrochemical cathodes produced thereby.
  • Metal/air batteries produce electricity by electrochemically coupling in a cell a reactive metallic anode to an air cathode through a suitable electrolyte.
  • an air cathode is a typically sheet-like member having opposite surfaces respectively exposed to the atmosphere and to an aqueous electrolyte of the cell/ in which (during cell operation) atmospheric oxygen dissociates while metal of the anode oxidizes providing a usable electric current flow through external circuitry connected between the anode and cathode.
  • the air cathode must be permeable to ait , but substantially hydrophobic (so that aqueous electrolyte will not seep or leak through it)/ and must incorporate an electrically-conductive element for external circuitry.
  • the air cathode is commonly constituted of active carbon (with or without cin added dissociation-promoting catalyst) containing a finely divided hydrophobic polymeric material and incorporating a metal screen as the conductive element.
  • active carbon with or without cin added dissociation-promoting catalyst
  • metal screen as the conductive element.
  • anode metals are used including iron/ zinc/ magnesium/ aluminum/ alloys of aluminum etc. Alloys of aluminum and magnesium are considered especially advantageous for particular applications owing to low cost/ lightweight and ability to function as anodes in metal/air batteries using neutral electrolytes/ such as sea water or other aqueous saline solutions.
  • Metal/air batteries have an essentially infinite shelf-storage life rendering them very suitable for standby or emergency uses in that the metal-air battery may be activated by immersing the electrode in an electrolyte.
  • bus bar cables are attached to the air cathode formed in accordance with the process of the aforementioned U.S. Letters Patent. Attachment of such bus bar cable involves the mechanical removal of areas of the carbon and teflon layers to expose the current collecting substrate, e.g., nickel grid for bus bar attachment thereto.
  • the bus bar cable to be soldered to the current collecting substrate requires the application or coating of a thin film of tin-lead alloy on the bus bar, generally copper braid as well as the use of tin-lead solder in the soldering process.
  • An object of the present invention is to provide an improved process for attaching bus bars to an air cathode.
  • Another object of the present invention is to provide an improved process for attaching bus bars to an air cathode permitting of efficient and effective attachment.
  • Still another object of the present invention is to provide an improved process for attaching bus bars to an air cathode eliminating the use of hazardous material.
  • Yet another object of the present invention is to provide an improved process for attaching bus bars to an air cathode readily adaptable to automatic processing.
  • a further object of the present invention is an improved bus bar/air cathode assembly of improved electrical characteristics.
  • a still further object of the present invention is an improved bus bar/air cathode assembly of more reproducible electric characteristics.
  • Figure 1 is a schematic elevational view of an electrochemical cathode of the present invention.
  • Figure 2 is a schematic cross-sectional view of the embodiment of the electrochemical cathode of Figure 1;
  • FIG. 3 is an exaggerated partial cross-sectional view of another embodiment of present invention.
  • Figure 4 is a cross-sectional view of the resulting assembly of the process of Figures 3;
  • Figure 5 is a cross-sectional view of a resulting assembly of the process of Figure 3 utilizing a clenching member.
  • an air cathode/ generally indicated as 10/ a laminate structure comprised of a metal mesh substrate 12/ reactive layers 14 laminated to the mesh substrate 12 and a hydrophobic microporous layer 16 mounted to an outer reactive layer 14.
  • the metal mesh 12 is the current collector of the air cathode 10/ and is formed of a suitable metallic material/ such as nickel/ stainless steel and the like/ formed for example by expanded metal techniques such as disclosed in the aforementioned U.S. Letters Patent No.
  • a suitable bus bar foil or strip 18/ extending the length of the outer reactive layer 14 and hydrophobic microporous layer 16/ and forming an upper end tab member 20
  • Suitable bus bar material includes foils or strips formed from copper, silver/ nickel/ steel/ aluminum/ brass and like conductive metals.
  • a riveting gun generally indicated as 22/ is positioned on the bus bar foil or strips and is comprised of a riveting head member 24 and a base member 26 for inserting a rivet 28 including cap portion 30 through a strip 18, thence through the air cathode 10 and finally/ through the other strip to form a flattened end portion 32 which cooperates with the cap 30 and thereby capture the air cathode 10 therebetween with the rivet 28 forming a mechanically strong/ low resistance contact with the current collecting substrate 12 of the air cathode 10.
  • the riveting protocol is continued to provide a rivet density of from about 1 to 10 per square inch of the copper foil strips. It will be understood by one of ordinary skill in the art that a riveted air cathod assembly may be formed with one copper foil riveted to one side of an air cathode.
  • FIG. 3 Another embodiment of the present invention is illustrated by Figure 3 with a like composite of an air cathode 10 and copper foils or strips 18 as discussed with reference to Figures 1 and 2 and utilizes a clenching assembly comprised of a clenching hammer 40 and a plate member 42 including a clenching cavity.
  • the clenching hammer 40 is caused to be driven or forced through the composite and into the clenching chamber 44 to effect mechanical fastening or a cinch at 46 similar to riveting whereby carbon and hydrophobic layers tear locally and establish mechanical and electrical contact with the current collecting grid and copper foils.
  • Clenching may be effected at like density/ i .e . , of from about 1 to about 10 per square inch.
  • a clenching member 48/ referring to Figure 5/ may be positioned on the clenching hammer 40 prior to penetration of the composite
  • TCR cells utilizing riveted copper bus bars of the present invention achieve like reproducibility of TCR cells produced by the tedious labor intensive procedure hereinabove disclosed.

Abstract

There is disclosed a process for forming a cathode assembly (10) including positioning bus bar components (18) on one or either side of an air cathode laminate and mechanically fastening together such components.

Description

DESCRIPTION
PROCESS FOR MANUFACTURING AN ELECTROCHEMICAL CATHODE WITH BUS BAR AND PRODUCTS PRODUCED THEREBY
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a process for manufacturing electrodes and electrodes produced thereby/ and more particularly to a process for manufacturing electrochemical cathodes for use in electrochemical cells and electrochemical cathodes produced thereby.
2. Description of the Prior Art
Metal/air batteries produce electricity by electrochemically coupling in a cell a reactive metallic anode to an air cathode through a suitable electrolyte. As is well known in the art, an air cathode is a typically sheet-like member having opposite surfaces respectively exposed to the atmosphere and to an aqueous electrolyte of the cell/ in which (during cell operation) atmospheric oxygen dissociates while metal of the anode oxidizes providing a usable electric current flow through external circuitry connected between the anode and cathode. The air cathode must be permeable to ait , but substantially hydrophobic (so that aqueous electrolyte will not seep or leak through it)/ and must incorporate an electrically-conductive element for external circuitry.
In present-day commercial practice/ the air cathode is commonly constituted of active carbon (with or without cin added dissociation-promoting catalyst) containing a finely divided hydrophobic polymeric material and incorporating a metal screen as the conductive element. A variety of anode metals are used including iron/ zinc/ magnesium/ aluminum/ alloys of aluminum etc. Alloys of aluminum and magnesium are considered especially advantageous for particular applications owing to low cost/ lightweight and ability to function as anodes in metal/air batteries using neutral electrolytes/ such as sea water or other aqueous saline solutions. Metal/air batteries have an essentially infinite shelf-storage life rendering them very suitable for standby or emergency uses in that the metal-air battery may be activated by immersing the electrode in an electrolyte.
In U.S. Patent No. 4,906/535, assigned to the same assignee as the present invention/ there is disclosed a process for producing an electrochemical cathode for an electrochemical cell comprised of a current collecting layer or substrate laminated between layers of a nonwoven conductive fibrous web/ preferably of conductive carbon fibers/ impregnated with a mixture of carbon particles and a nonfibrous polymeric substance/ and optionally with a hydrophobic microporous film or layer disposed on one of the layers of the nonwoven conductive fibrous web as well as the product produced thereby.
In the manufacture of metal-air and fuel cells/ as well as "book-cover cathodes" for telecommunications reserve cells (TCR)/ bus bar cables are attached to the air cathode formed in accordance with the process of the aforementioned U.S. Letters Patent. Attachment of such bus bar cable involves the mechanical removal of areas of the carbon and teflon layers to expose the current collecting substrate, e.g., nickel grid for bus bar attachment thereto. The bus bar cable to be soldered to the current collecting substrate requires the application or coating of a thin film of tin-lead alloy on the bus bar, generally copper braid as well as the use of tin-lead solder in the soldering process.
Such bus bar attachment protocol is inefficient/ time-consuming/ labor intensive/ involves the use of hazardous substance/ i . e . , lead and concomitant hazardous waste disposal problems and is not readily adaptable for automation and cost reductions attendant therewith. OBJECTS OF THE PRESENT INVENTION
An object of the present invention is to provide an improved process for attaching bus bars to an air cathode.
Another object of the present invention is to provide an improved process for attaching bus bars to an air cathode permitting of efficient and effective attachment.
Still another object of the present invention is to provide an improved process for attaching bus bars to an air cathode eliminating the use of hazardous material.
Yet another object of the present invention is to provide an improved process for attaching bus bars to an air cathode readily adaptable to automatic processing.
A further object of the present invention is an improved bus bar/air cathode assembly of improved electrical characteristics.
A still further object of the present invention is an improved bus bar/air cathode assembly of more reproducible electric characteristics. SUMMARY OF THE INVENTION
These and other objects of the present invention are achieved in a process for forming a cathode assembly including positioning bus bar components on one or either side of an air cathode laminate and mechanically fastening together such components. BRIEF DESCRIPTION OF THE DRAWINGS
Other features and advantages of the present invention will become more readily apparent from the following detailed description when taken with the accompanying drawings wherein:
Figure 1 is a schematic elevational view of an electrochemical cathode of the present invention; and
Figure 2 is a schematic cross-sectional view of the embodiment of the electrochemical cathode of Figure 1;
Figure 3 is an exaggerated partial cross-sectional view of another embodiment of present invention;
Figure 4 is a cross-sectional view of the resulting assembly of the process of Figures 3; and
Figure 5 is a cross-sectional view of a resulting assembly of the process of Figure 3 utilizing a clenching member. DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawing/ there is illustrated an air cathode/ generally indicated as 10/ a laminate structure comprised of a metal mesh substrate 12/ reactive layers 14 laminated to the mesh substrate 12 and a hydrophobic microporous layer 16 mounted to an outer reactive layer 14. The metal mesh 12 is the current collector of the air cathode 10/ and is formed of a suitable metallic material/ such as nickel/ stainless steel and the like/ formed for example by expanded metal techniques such as disclosed in the aforementioned U.S. Letters Patent No.
Figure imgf000006_0001
Proximate the center line and on either side of the air cathode 10/ there is positioned a suitable bus bar foil or strip 18/ extending the length of the outer reactive layer 14 and hydrophobic microporous layer 16/ and forming an upper end tab member 20 Suitable bus bar material includes foils or strips formed from copper, silver/ nickel/ steel/ aluminum/ brass and like conductive metals.
A riveting gun; generally indicated as 22/ is positioned on the bus bar foil or strips and is comprised of a riveting head member 24 and a base member 26 for inserting a rivet 28 including cap portion 30 through a strip 18, thence through the air cathode 10 and finally/ through the other strip to form a flattened end portion 32 which cooperates with the cap 30 and thereby capture the air cathode 10 therebetween with the rivet 28 forming a mechanically strong/ low resistance contact with the current collecting substrate 12 of the air cathode 10. The riveting protocol is continued to provide a rivet density of from about 1 to 10 per square inch of the copper foil strips. It will be understood by one of ordinary skill in the art that a riveted air cathod assembly may be formed with one copper foil riveted to one side of an air cathode.
Another embodiment of the present invention is illustrated by Figure 3 with a like composite of an air cathode 10 and copper foils or strips 18 as discussed with reference to Figures 1 and 2 and utilizes a clenching assembly comprised of a clenching hammer 40 and a plate member 42 including a clenching cavity. The clenching hammer 40 is caused to be driven or forced through the composite and into the clenching chamber 44 to effect mechanical fastening or a cinch at 46 similar to riveting whereby carbon and hydrophobic layers tear locally and establish mechanical and electrical contact with the current collecting grid and copper foils. Clenching may be effected at like density/ i .e . , of from about 1 to about 10 per square inch. Likewise/ only one (1) copper foil or strip 18 may be used in the composite prior to clenching of the composite. Additionally, a clenching member 48/ referring to Figure 5/ may be positioned on the clenching hammer 40 prior to penetration of the composite
TCR cells utilizing riveted copper bus bars of the present invention achieve like reproducibility of TCR cells produced by the tedious labor intensive procedure hereinabove disclosed.
While the present invention has been described with reference to the coupling of a strip of bus bar material for an air cathode of a specific layered configuration/ it will be understood by one of ordinary skill in the art that other cathode structures including reactive layers of other materials including MnO_/ AgO, CaCl./ and the like laminated to a current-collecting layer or grid/ may be processed in accordance with the present invention.

Claims

1. A process for attaching a bus bar to a cathode laminate including a current collecting layer/ which comprises: positioning a strip of bus bar material proximate said cathode laminate; and mechanically coupling portions of said bus bar strip to said current-collecting layer of said cathode.
2. The process as defined in Claim 1 wherein mechanical coupling includes rivets forcing a rivet member through said composite and forming a flattened end portion at a distol end thereof thereby capturing said cathode laminate and said strip.
3. The process as defined in Claim 1 and including the step of positioning bus bar strips on both sides of said laminate prior to mechanical coupling.
4. The process as defined in Claim 2 and including the step of positioning bus bar strips on both sides of said laminate prior to mechanical coupling.
5. The process as defined in Claim 1 wherein mechanical coupling comprises the insertion of a clinching member through said laminate and said strip of bus bar material to effect mechanical and electrical contact between said current-collecting layer and said strip of bus bar material.
6. The process as defined in Claim 5 including the steps of positioning bus bar strips on both sides of said laminate prior to mechanical coupling.
7. The process as defined in Claim 1 wherein mechanical coupling is effected to a density of from 1 to 10 per square inch of said strip of bus bar material.
8. The process as defined in Claim 2 wherein mechanical coupling is effected to a rivet density of from 1 to 10 per square inch of said strip of bus bar material.
9. The process as defined in Claim 5 wherein mechanical coupling is effected to a clinching density of from 1 to 10 per square inch of said strip of bus bar material.
10. A cathode assembly/ which comprises: a cathode substrate including a current-collecting layer; and a strip of bus bar material mechanically coupled to said current-collecting layer.
11. The cathode assembly as defined in Claim 10 and further including a strip of bus bar material mechanically coupled on both sides of said cathode substrate to said current-collecting layer thereof.
12. The cathode assembly as defined in Claim
10 wherein said cathode substrate includes carbon layers positioned on either side of said current-collecting layer and a hydrophobic layer bonded to a carbon layer.
13. The cathode assembly as defined in Claim
11 wherein said cathode substrate includes carbon layers positioned on either side of said current-collecting layer and a hydrophobic layer bonded to a carbon layer.
14. The cathode assembly as defined in Claim
10 wherein said bus bar material is copper.
15. The cathode assembly as defined in Claim
11 wherein said bus bar material is copper.
16. The cathode assembly as defined in Claim
12 wherein said bus bar material is copper.
17. The cathode assembly as defined in Claim 10 wherein rivets mechanically couple said strip of bus bar material to said current-collecting substrate.
18. The cathode assembly as defined in Claim
10 wherein portions of said strip of bus bar material is forced into contact with said current-collecting layer.
19. The cathode assembly as defined in Claim
11 wherein rivets mechanically couple said strip of bus bar material to said current-collecting substrate.
20. The cathode assembly as defined in Claim 11 wherein portions of said strip of bus bar material is forced into contact with said current-collecting layer.
PCT/US1993/007089 1992-07-30 1993-07-28 Process for manufacturing an electrochemical cathode with bus bar and products produced thereby WO1994003933A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US92215592A 1992-07-30 1992-07-30
US07/922,155 1992-07-30

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WO1994003933A1 true WO1994003933A1 (en) 1994-02-17

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN1115926C (en) * 1995-06-19 2003-07-23 艾利森公司 Multiple user base stations and methods for their operation method

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3269863A (en) * 1965-07-02 1966-08-30 Gen Motors Corp Storage battery plate
US4087596A (en) * 1976-06-16 1978-05-02 Varta Batterie Aktiengesellschaft Positive electrode for air/zinc elements
US4119771A (en) * 1975-06-04 1978-10-10 Volkswagenwerk Aktiengesellschaft Negative cobalt electrode for an alkaline storage battery
US4906535A (en) * 1987-07-06 1990-03-06 Alupower, Inc. Electrochemical cathode and materials therefor
US5154993A (en) * 1990-04-27 1992-10-13 Eveready Battery Company, Inc. Electrode strips for coiled assemblies and method of producing them

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3269863A (en) * 1965-07-02 1966-08-30 Gen Motors Corp Storage battery plate
US4119771A (en) * 1975-06-04 1978-10-10 Volkswagenwerk Aktiengesellschaft Negative cobalt electrode for an alkaline storage battery
US4087596A (en) * 1976-06-16 1978-05-02 Varta Batterie Aktiengesellschaft Positive electrode for air/zinc elements
US4906535A (en) * 1987-07-06 1990-03-06 Alupower, Inc. Electrochemical cathode and materials therefor
US5154993A (en) * 1990-04-27 1992-10-13 Eveready Battery Company, Inc. Electrode strips for coiled assemblies and method of producing them

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN1115926C (en) * 1995-06-19 2003-07-23 艾利森公司 Multiple user base stations and methods for their operation method

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