NICKEL-CADMIUM BATTERY CELL WITH IMPROVED ELECTROLYTE RESERVOIR

Abstract: Nickel-cadmium battery cell (10) has a plurality of cadmium negative electrode plates (24), (26) and (28) and a plurality of alternate nickel positive electrode plates (30) and (32). The separator space therebetween is occupied by separators (34), (36), (38) and (40). The enhanced thickness of the separator space, more than 200 microns, serves as a reservoir which provides an increased amount of potassium hydroxide electrolyte so that as the nickel electrode grows during cycling and withdraws electrolyte from the separator by compression or crushing of the separator and by capillary action into the nickel electrode, sufficient electrolyte remains for an enhanced battery cell life. The increased interelectrode spacing also increases lifetime limited by short circuiting due to cadmium interelectrode deposits. Another embodiment employs an electrolyte reservoir positioned laterally of the electrode stack and formed of foamed material so that upon growth of the nickel electrodes, the foam crushes to permit maintenance of the separator space and supply electrolyte.

Description: NICKEL-CADMIUM BATTERY CELL WITH IMPROVED ELECTROLYTE RESERVOIR BACKGROUND OF THE INVENTION This invention is directed to the construction of alkaline battery cells such as battery cells having nickel and cadmium electrodes and potassium hydroxide electrolyte. The configuration includes a highly electrolyte retaining and dual pored separator which is more thick in the direction between electrodes than in state-of-the-art cells to permit greater electrolyte storage and thereby reduce the degree of dry-out problems of separators and electrodes, lengthen the distance between the electrodes to reduce shorting problems by cadmium bridge formation between the electrodes and to decrease the proportion of compression caused by electrode growth to reduce separator compaction which decreases the electrode spacing. Alkaline battery cells are known and a discussion of their properties and particularly the separators are found in Hong S. Lim et al, U.S. Patent No. 4,233,347, Howard H. Rogers, U.S. Patent No..4,262, 061 and Scott A. Verzwyvelt, U.S. Patent No. 4,308,325. In addition, various papers have been published, including "New Separators for Nickel-Cadmium Cells" H. S. Lim et al, published by the American Society of Mechanical Engineers in the "Proceedings of the Sixtenth Intersociety Energy Conversion Engineering Conference", Vol. 1 on August 9, 1981 at pages 182-186. - JΕs r O PI Among problems that limit the life of nickel- cadmium cells are (1) creation of a situation that there is insufficient amount of electrolyte in separator ("separator dryout" ) and nickel electrode and (2) elec- trical short formation due to cadmium deposits in the separator which is caused by cadmium migration from the cadmium electrode into the separator. The partial dryout condition of separator and electrodes is caused by slow expansion of nickel electrode and thereby creates voids in the electrodes. A typical nickel electrode which is used in state-of-art spacecraft nickel-cadmium cells expands by 30 to 40% of the original thickness at the end of its life. Therefore, it is desired to have increased amount of electrolyte in the cell to begin with. The limitation to the increased amount is the fact that (1) there is limited space in the separator for the electrolyte reservoir because of relatively narrow spacing between electrodes and (2) the separator cannot be flooded with electrolyte because oxygen gas passage is needed through the separator. If the oxygen gas passage is impeded, oxygen pressure may build-up to an unacceptable level (for example, rupture the case by high pressure) . In state-of-art spacecraft batteries typical values of separator (nylon or polyproylene felts) thickness between the nickel and cadmium elec¬ trodes range from 150 to 200 microns while those of the electrodes range 650 to 1000 microns. Therefore, 20% expansion of nickel electrode, for example, should create enough void volume in the electrode to change the electrolyte distribution significantly and also compact the separator and thereby reduce the electrode spacing significantly. Batteries with such cells can be used in space¬ craft. While long-life spacecraft carry solar-electric cells, the spacecraft are periodically eclipsed so that O PI a battery is necessary for continuous power supply in the spacecraft. Futhermore, in spacecraft it is essen¬ tial to maximize output with respect to weight because of the expense of lifting weight into orbit. Spacecraft cells thus have moved along a development path which reduces weight by minimizing electrode and separator thickness. A long-life nickel-cadmium battery is desired for long-life spacecraft, such as geosynchronous communication satellites. In the past, the life of the satellite has sometmes been limited by the life ' of the battery. SUMMARY OF THE INVENTION In order to aid in the understanding of this invention it can be stated in essentially summary form that it is directed to an alkaline battery cell wherein a larger spacing between the electrodes and a correspond¬ ingly thicker separator in the interelectrode spacing are provided. This increased separator spacing is opposite to state-of-art practice where separator spacing is minimized to reduce the resistive component across the separator. In the prior art, the resistive component increases proportionately with increasing separator spacing. Furthermore, prior art battery design minimized separator spacing to reduce the amount of battery electrolyte weight required to fill the separator void areas. However, the present invention allows for a new generation of separator material that allows increased separator spacing without an increased resis¬ tive component. That is to say, zirconium oxide based separator structure demonstrates lower resistance than prior art material such as nylon or polypropylene. It is thus a purpose of this invention to provide an alkaline battery cell which has a reduced weight by operating through deeper discharge cycles and to enhance the life of the battery cell and the battery in which it is incorporated. This purpose of the invention is achieved by providing a thicker separator which is highly electrolyte retaining and has dual pore structure between the battery electrodes to increase electrolyte storage and thereby reducing the degree of the separator dryout, increase the distance between electrodes such that the cadmium migration shorting is reduced and the degree of compression of the separator as the electrodes expand is also reduced. The dual pore structure of the separator is necessary order to load the maximum amount of electrolyte in the separator without blocking the oxygen gas passage. Other purposes and advantages of this invention will become apparent from a study of the following portion of this specification, the claims and attached drawings. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a perspective view of the battery in accordance with this invention, with the case partially broken away. FIG. 2 is a side elevational view with the battery case broken away of some of the battery plates and the separators therebetween. FIG. 3 is a side elevational view of a second preferred embodiment of the battery of this invention, with the case broken away and showing in section some of the battery electrodes and separators as well as an electrolyte reservoir between the electrodes and the case. DETAILED DESCRIPTION OF THE INVENTION An alkaline battery cell in accordance with this invention is generally indicated at 10 in FIG. 1. The battery cell 10 comprises a case 12 which completely encloses the active and structural elements of the battery therein. Cover 14 has terminal posts 16 and 18. Terminal post 16 is connected to the cover. Terminal post 18 is mounted on insulating bushing 20 so that the terminal post 18 passes through the cover and is insulated with respect thereto. Terminal 18 is the positive terminal. Tube 22 is connected to an opening in the cover 14. This tube is used to fill electrolyte onto the cell. As is seen in FIG. 2, there is a plurality of battery electrodes and separators within case 12. In the preferred embodiment of the battery of this inven¬ tion, the negative electrodes are made of cadmium active material imbedded in nickel-sinter plates, the positive electrodes are made of nickel active material imbedded in nickel sinter plates and the electrolyte is potassium hydroxide solution with or .without additives. FIG. 1 shows the stack of electrodes and FIG. 2 shows at least some of the stack of electrodes in an enlarged crosssection. Negative electrodes 24, 26 and 28 are shown and alternate positive electrodes 30 and 32 are shown. Separators 34, 36, 38 and 40 are positioned between the electrodes. The nickel electrodes are packed with nickel hydroxide which is the electroactive material. The individual electrodes are connected to the terminal post by connector busses individually attached to the electrodes adjacent the top thereof. The busses are collected together and attached to the terminals. See the top edge of the electrodes in both FIGS. 1 and 2. An ideal class of materials for these reservoir separators is the polymer reinforced zirconia fabrics described in H. S. Lim, H. H. Rogers and S. A. Verzwyvelt, U.S. Patent No. 4,23,347 and Scott A. Verzwyvelt, U.S. Patent No. 4,308,325 and Howard H. Rogers, U.S. Patent No. 4,262,061, the entire disclo¬ sures of which are incorporated herein by this reference. The separators have a woven fabric structure with openings up to several hundred micrometers (microns) in diameter, with the openings extending across the fabric. The woven fabric also has small pores of 10 micrometers or less. The small pores are effective for causing this material to strongly retain the electrolyte and compete for it against the porous electrodes. Thus, this material shows high electrolyte retention capability. In addition, the larger openings permit gaseous oxygen bubbles to pass through the separator. The separators thus serves as a porous material which can hold electro¬ lyte and release it as required. The separators serve as a reservoir which should be able to hold enough electrolyte for a combination of the physical changes in the cell, without blocking oxygen passage through them. The zirconium fabrics provide the desired physical properties, but are too weak for high vibration uses. Zirconia fabrics which are reinforced with polysulfone (Z-PS) or reinforced with polybenzi idazole (Z-PBI) or other organic reinforcing materials are the preferred embodiment for the battery of this invention which is subjected to vibrational stresses, such as found in spacecraft. The polysulfone and polybenzimidazole have been tested and found useful in reinforcing zirconia. It is thought that other polyfluorinated hydrocarbons such as polytetrafluoroethylene (PTFE) would provide the necessary reinforcing and would be stable in - miTEX OMPI potassium hydroxide electrolyte and would also retain considerably more electrolyte than the previously used nylon separator in a dry stack condition. The dry stack condition is a physical condition which occurs when the individual nickel electrodes expand through repeated cycling. This expansion creates pores in the electrode which take the electrolyte away from the separators through capillarly action. Testing found that nickel electrodes with chemically deposited nickel hydroxide expand about 30% of the original thickness after about 3000 charge-discharge cycles at a 60% depth-of-discharge operation. This expansion of the nickel electrode causes squeezing of the separator to express out the electrolyte. Furthermore, the pore distribution changes in the nickel electrodes throughout their life period. New electrodes, especially electro-deposited nickel electrodes showed a high distribution of pores in the diameter range of 0.2 to 10 microns. After 3000 cycles the pore distribution in this range was drastically reduced while the distribution in the range of 0.01 to 0.1 microns was tremendously increased. The smaller pores have a higher retention of the electrolyte so that during cycling release of the electrolyte from the pores is more difficult. For these several reasons, it is desirable to provide a battery cell which includes a thicker separator and increased amount of electrolyte over the state-of-art cells. The electrode spacing is about 150 to 200 microns in present day nickel-cadmium cells employing modern nylon separators. In the pre¬ sent structure, in accordance with this invention, the electrode spacing is more than 200 microns, such as 250 microns or larger. This spacing is large enough so that the electrode spacing will still be from 150 OMPI to 200 microns even after a typical (about 680 microns thick when new) nickel electrode is expanded by 30%. In the present design, separators which have dual pore structure are used to hold the maximum amount of electro- lyte in the given space without blocking the oxygen gas passage. The result is an increase in life-time so that the life of the battery cells in accordance with this invention is up to three times as long as the prior art nickel-cadmium cells with nylon separators. This is because the important life limiting mechanisms are the component dryout caused by the expansion of the nickel electrodes and short formation by cadmium migration as the cell is cycled. The expansion creates the large volume of pores in the nickel electrode in the small pore size range which absorbs the potassium hydroxide electrolyte through capillary action from the separator, which has much larger pore size than the electrodes. As a result of this shiξt of the electrolyte, the separators in the conventional battery become dry causing functional degradation of the cell. The thicker starting separator thickness with its greater electrolyte capacity improves the life by providing additional electrolyte reservoir capability for this nickel electrodes expansion. Furthermore, the new generation zirconium oxide separator has a dual pore structure where one set of pores is much smaller than the pores in state-of-art nylon and poly¬ propylene separators. This smaller pore structure competes more favorably with the nickel electrode for electrolyte. It has been experimentally demonstrated that zirconium based separators compete much more success¬ fully for electrolyte than nylon or polypropylene separators. Another life limiting mechanism is the occurrance of internal shorts caused by cadmium migration from the negative cadmium electrode to the separator. The cell becomes shorted when the migrated cadmium is accumulated in the separator in sufficient quantity to form a cadmium bridge between the positive and negative electrodes. The time required for this short formation depends on temperature and electrode separation, which is the thickness of the separator. At the usual 10°C ambient temperature found in spacecraft, cadmium bridging is not usually a life-limiting factor. In uses where the ambient may be 30°C, it may cause shorting. With the increased electrode separation in the cell of the present invention, the life-time of the cell is considerably increased. The following table compares separator material, nickel electrode manufacturing method and various temperature and depth of discharge conditions with the life obtained in a present day nickel-cadmium cell with nylon separator. The cell types in accordance with this invention which were tested include CD: chemically deposited nickel electrodes, ED: electrochemically deposited nickel electrodes, Z-PS: polysulfone rein¬ forced zirconia separators and Z-PBI: polybenzimidazole reinforced zirconia separators. Cells in accordance with this invention were tested with initial electrode spacing of 300 and 250 micrometers under several temperature test conditions and 40%, 60% and 80% depth of discharge. The last column of the table shows the life expected in state-of-the art nylon cells which is the one described above with inital electrode spacing from 150 to 200 micrometers. ^\ £A OMPI ° * 10 TABLE I Cycle Life of State- Initial of-Art Nylon Electrode Cell Compar¬ Cell Spacing Test Cycle able Test Type Microns Conditions Life Conditions CD/Z -PS 300 25°C; 40% DOD >30,000 9,800 CD/Z -PS 300 25°C; 40% DOD >30,000 9,800 CD/Z -PS 300 40°C? 40% DOD 16,252 5,200 CD/Z -PS 300 40°C? 40% DOD 16,262 5,200 CD/Z -PS 300 50°C; 40% DOD 11.415 3,700 CD/Z -PS 300 50°C; 40% DOD 11,415 3,700 CD/Z-PS 300 50°C; 40% DOD 9,680 3,700 ED/Z -PS 250 40°C? 60% DOD 8,276 3,200 ED/Z -PS 250 40° C; 60% DOD 5,838 3,200 ED/Z-PBI 250 40°C; 60% DOD 5,051 3,200 ED/Z-PBI 250 40°C; 60% DOD 5,139 3,200 ED/Z-PS 250 25°C; 80% DOD > 6,800 2,500 ED/Z-PBI 250 25°C; 80% DOD 6,255 2,500 OMPI The structure in FIG. 3 illustrates a battery cell 42 wherein the electrolyte reservoir is positioned away from the separators. If desired, separators having more than the minimum thickness may be employed, but in the cell 42 both the additional electrolyte supply and the capability for accommodating the expanding nickel electrodes is achieved outside of the electrode stack. Case 44 contains therein a stack of electrodes and separators the same as illustrated in FIG. 2 with respect to battery cell 10, and they carry the same numbers. Positioned between the outer, negative, cadmium electrodes 24 and 28 and the case 44 are respectively reservoir sponges 46 and 48. If it is desired that the case 42 operate at a different potential than the outer negative electrodes 24 and 28, an insulator sheet 50 may be provided. The insulator sheet 50 is in the form of a sleeve wrapped around the reservoir sponges and electrodes. Polypropylene is a suitable material. Such a sheet may be also employed for the same purpose i n battery cell 10. Reservoir sponges 46 and 48 are structures which are compatible with the potassium hydroxide electrolyte have the compressibiliity which permits them to compress when the nickel electrodes expand, and have a pore structure such that they can retain electrolyte without flooding the cell and release the electrolyte as the electrode expands. Suitable materials include poly¬ propylene foam, nickel foam or sinter, polypropylene felt, zirconium oxide cloth, etc. Such material can be made with 80% voids and with a compressive strength sufficiently low that the foam crushes as the nickel electrodes expand. Thus, the compressible material has a dual function. One function is limiting the lateral build-up of forces within the battery cell, in a direc- tion normal to the electrodes. The forces are limited because as the nickel electrodes expand, the foam reser¬ voir sponge crushes so that the separators between the electrodes are not compressed to a smaller thickness. Depending on the material, the crushing may be resilient or non-resilient. The other function is as an electrolyte reservoir in the battery. The pores of the reservoir foam are initially filled with the electrolyte and then the electrolyte is slowly squeezed out as the nickel electrodes expand. The electrolyte squeezed out of the foam will fill the voids which are formed in the nickel electrodes as they expand. By this mechanism, the separator dry-out by loss of the electro¬ lyte is also prevented. With the reduction in electrolyte dry-out in the separators, cadmium migration into the separators is also reduced so that it is reduced as a life limiting mechanism. This invention has been described in its presently contemplated best mode and it is clear that it is susceptible to numerous modifications, modes and e bodi- ments within the ability of those skilled in the art and without the exercise of the inventive faculty. Accordingly, the scope of this invention is defined by the scope of the following claims. OMPI

Claims: 13 CLAIMS What is Claimed is: 1. A nickel-cadmium battery cell comprising: a plurality of spaced alternate nickel and cadmium electrodes to define interelectrode spaces; a separator in each of said interelectrode spaces, said separators being for retaining potassium hydroxide electrolyte and permitting transit of oxygen gas; a battery case surrounding said electrodes and separators for maintaining electrolyte in said separators; and a reservoir space within said battery case, said reservoir space having a porous material therein and electrolyte within said porous material, said porous material being positioned to reduce in thickness to accommodate for a nickel electrode expansion during repeated electrical cycling of said battery cell. 2. The battery cell of Claim 1 wherein said reservoir is positioned between said electrode and said case. 3. The battery cell of Claim 1 wherein said reservoir is made of a material which is compatible with potassium hydroxide, is at least as compressible as the separator material, and has a pore structure such that it can retain electrolyte without flooding the cell and release the electrolyte as the electrode expands. 4. The battery cell of Claim 3 wherein said material is selected from the group consisting of metal foam and synthetic polymer composition material foam. 14 5. The battery cell of Claim 3 wherein said material is selected from the group consisting of polymer felts and metal oxide cloth. 6. The battery cell of Claim 1 wherein said reservoir is within said separator in extra thickness of said separator. 7. A nickel-cadmium battery cell comprising: a plurality of spaced alternate nickel and cadmium electrodes to define interelectrode spaces; a separator in each of said interelectrode spaces, said separators being for retaining potassium hydroxide electrolyte and passing oxygen gas, said separators being compressible and sufficiently thick in the direction between electrodes to prevent separator dryout during repeated electrical cycling of said battery cell. 8. The battery cell of Claim 7 wherein said electrodes are spaced apart at least 250 microns. 9. The cell of Claim 7 wherein said separator is made substantially of zirconia fabric. 10. The cell of Claim 9 wherein said separator is reinforced with an organic polymer. 11. The cell of Claim 7 wherein said separator is made of zirconium fabric and said separator is rein¬ forced by an organic polymer which is alkali stable and is wettable by potassium hydroxide. _ OMPI 15 12. The cell of Claim 7 wherein said separator is made of zirconium fabric and said separator is rein¬ forced by an organic polymer selected from the group consisting of polysulfone and polybenzimidazole. 13. The battery cell of Claim 7 wherein the initial spacing between said electrodes is greater than 200 microns to provide potassium hydroxide electrolyte reservoir capacity. 14. The battery cell of Claim 9 wherein the initial spacing between said electrodes is greater than 200 microns to provide potassium hydroxide electrolyte reservoir capacity. 15. The battery cell of Claim 10 wherein the initial spacing between said electrodes is greater than 200 microns to provide potassium hydroxide electrolyte reservoir capacity. 16. The battery cell of Claim 11 wherein the initial spacing between said electrodes is greater than 200 microns to provide potassium hydroxide electrolyte reservoir capacity. 17. The battery cell of Claim 7 wherein the initial spacing between said electrodes is at least 250 microns to provide potassium hydroxide electrolyte reservoir capacity. 18. The battery cell of Claim 10 wherein the initial spacing between said electrodes is at least 250 microns to provide potassium hydroxide electrolyte reservoir capacity. 16 19. The battery cell of Claim 11 wherein the initial spacing between said electrodes is at least 250 microns to provide potassium hydroxide electrolyte reservoir capacity. OMPI V.IPO

Inventors: LIM HONG S, VERZWYVELT SCOTT A, LIM, HONG, S., VERZWYVELT, SCOTT, A.
Applicants: HUGHES AIRCRAFT CO, HUGHES AIRCRAFT COMPANY
Application year: 1983
Main classification: H01M10
IPC codes: H01M10