METHOD OF MAKING A BATTERY

Abstract: A method for making a battery in which a molded container (12) is formed with a plurality of cell cavities (30). Folded electrodes (36, 38) are inserted in the cavities (30), and a container cover (22) is ultrasonically welded to the container (12) to hermetically seal the cell cavities (30). In order to form a leakproof battery in a minimum of steps, the container cover (22) is formed with conductive inserts (50, 52, 54) embedded therein which form the intercell electrical connections and the connections between the cells (14) and the battery terminals (27, 29).

Description: -1- METHOD OF MAKING A BATTERY The present invention relates to a method of making a battery, and more particularly, to a method r 5 of forming a hermetically—sealed battery from a plastic material. In the production of relatively small batteries for use in portable items, such as cameras, it is necessary to make the batteries with as few 10 steps as possible to minimize cost. However, the batteries must be made by methods that will insure that the battery will be leakproof over the life of the battery. Such batteries normally include a plurality of cells, and one of the main problems is 15 in making leakproof electrical connections between cells and between the cells and the battery terminals. One known method of making batteries is to form individual sealed cells and to electrically connect the individual cells. Such a method is time 20 consuming and is too expensive for most types of batteries. U. S. Patent No. 4,121,017, discloses a battery in which separate cell compartments are formed in a molded plastic container. Folded plates 25 are placed in the compartments, and a container cover is sealed over the compartments. The positive and negative plates of adjacent cells are electrically connected through a common wall, and the battery terminals are joined to the cells through connections 30 in special channels at opposite sides of the battery. A problem with this method of construction -*- is that a complex welding procedure must be used to make the intercell connections and the connections * between the cells and the battery terminals. 35 Further, since the intercell connections are made through the cell wall, it is very difficult to make the connections leakproof over the life of the battery. British Patent Specification No. 510,238, discloses an electric storage battery in which pole connections are embedded in a cell cover, and the pole connections have extensions which are welded to lugs of positive and negative plates in the battery cells. Grooves are formed in the lower face of the cover and are filled in with a mass which serves for sealing the walls of the cells against the cell cover. Fill holes are provided in a top wall for adding fluid to the battery. Such a construction is not suitable for use in forming hermetically—sealed batteries, such as lithium batteries, which must remain permanently sealed over long periods of use. It is an object of the present invention to overcome the problems in the prior art discussed above and to provide a method of manufacturing a battery which is relatively inexpensive and produces a hermetically—sealed battery. In accordance with one aspect of the invention, there is provided a method of making a battery, said method comprising the steps of: forming a container having a plurality of cavities therein; injecting heated plastic into a mold having heated electrically—conductive inserts therein to form a battery cover; inserting electrodes in each of said cavities to form a plurality of cells, said electrodes being arranged in said cavities such that terminals thereof are located adjacent an opening of each of the cavities; joining said terminals of each cell to said conductive inserts to form electrical connections between said cells and between battery terminals on said battery cover; and ultrasonically welding said battery cover to said container. In accordance with a further aspect of the invention, there is provided a method of making a cover from a plastic for use in a battery, the method comprising the steps of: placing electrically < f * 5 conductive inserts in grooves in a mold such that first portions of said inserts are exposed and second portions are contained in said grooves; heating the inserts to a temperature sufficient to activate chemical bonding between said inserts and the 10 plastic; and injecting heated plastic into the mold to form a cover in which the first portions of the inserts are embedded in the plastic and bonded thereto and said second portions are exposed. In one embodiment of the invention, a 15 battery is formed by first molding a plastic container having a plurality of cell cavities therein. Folded electrodes are inserted in the cell cavities such that the electrode terminals extend from each cavity. A battery cover is formed with a 20 plurality of conductive inserts molded therein. The inserts are joined to electrode terminals of the individual cells to form the connections between cells and the connections for the battery terminals. The battery cover is joined to the container by 25 ultrasonic means to hermetically seal the cells. Certain types of batteries, for example, lithium-Mn0 2 batteries, are designed to have a shelf life of several years. It is especially important in these types of batteries that the 30 battery be hermetically sealed, not only to prevent leakage of electrolyte, but also to maintain battery ^y strength during long periods of storage. A principal advantage of the present invention is that a hermetically sealed battery can be produced in 35 relatively few steps. As a result of molding the electrically—conductive inserts in the container -4- cover, the internal electrical connections in the battery can be made in a single step, and all of the cells can be sealed by affixing the container cover to the container. Further, since the electrical connections are contained in the individual elements of the battery, the disclosed method is particularly suitable for use in high—speed, automated assembly equipment. Applicants' method can be practiced in making batteries having a single cell as well as multicell batteries. Embodiments of the present invention will now be described, by way of example, with reference to the accompanying drawings in which: Fig. 1 is an exploded perspective view of a battery made by the present invention; Fig. 2 is an elevational view, in section, of a single cell of the battery; Fig. 3 is a sectional view taken along the line 3-3 in Fig. 2; Fig. 4 is a top plan view of the container, showing the arrangement of the electrodes in each cell cavity; Fig. 5 is a bottom plan view of the container cover; Fig. 6 is a sectional view taken along the line 6-6 in Fig. 5; Fig. 7 is a sectional view taken along the line 7-7 in Fig. 5; Fig. 8 is a plan view of a mold cavity for forming the covers; and Fig. 9 is a sectional view taken along the line 9-9 in Fig. 8. The method of the present invention is described hereinafter with reference to a lithium— manganese dioxide battery. It will be apparent, however, that the present invention can be used in making other types of batteries. With reference to Fig. 1, there is shown a battery 10 constructed in accordance with the method of the present invention. Battery 10 comprises a container 12 which includes three cells 14. A battery cover 20 comprises a container cover 22 and a terminal plate 26 having a positive terminal 27 and a negative terminal 29. Container 12 is formed, for example, by conventional injection molding techniques from a material such as polypropylene having a reinforcing filler. One suitable material is polypropylene having a reinforcing filler of about 20% chopped glass. Container 12 is formed with three cavities 30. As shown in Figs. 1—4, each of the cell cavities 30 contains an electrode assembly 34 which includes an anode 36, a cathode 38, and a separator (not shown). Anode 36 can be formed as a laminate structure (not shown) having two or three layers in which lithium is coated on a one mil stainless steel foil collector. A portion of the stainless steel foil is left uncoated to form an anode terminal 40. A porous, electrically—insulating material, such as Celgard m 4510, is rolled over the lithium to form a separator. Cathode 38 is also a laminate structure (not shown) and comprises a stainless steel grid collector coated on one or both sides with a mixture of Mn0 2 , carbon and Teflon m 23. A small portion of the collector is left uncoated to function as a cathode terminal 42. Electrode assembly 34 is formed by positioning cathode 38 on top of an anode 36 such that they are not in electrical contact, and folding the assembly into a form suitable for insertion into a cavity 30. One example of a suitable form is the accordian— olded assembly 34 shown in Fig. 2. A more complete description of the electrode assembly 34 is provided in European Patent Application No. 86303664.6. As will be apparent from the discussion that follows, each of the cells 14 is hermetically sealed. Thus, it is preferred to incorporate a thermal fuse (not shown) in electrode assembly 34 to insure against the rupture of container 12 in the event of a short circuit or other malfunction. As shown in Fig. 1 and 5—7, container cover 22 comprises two U—shaped inserts 50 which are used to form the electrical connections between adjacent cells 14. Cover 22 also contains inserts 52 and 54 which are used to connect a cathode terminal 42 and an anode terminal 40 respectively and which also serve to form the electrical connections with terminal plate 26. It will be seen that inserts 52 and 54 extend through the entire thickness of cover 22, and thus, the material of cover 22 must be securely bonded to the inserts 50, 52, to provide a leakproof cover. As shown in Figs. 5—7, ridges 53 are formed on a bottom side of cover 22; ridges 53 serve as energy concentrators in a step, described later, in which cover 22 is ultrasonically welded to container 12. The ridges 53 are formed to have an included angle of approximately 90° which has been found to maximize flow in the weld process without giving excess flash. An important element of the present invention is the method of forming container cover 22 with inserts 50, 52 and 54 molded therein to obtain a - fluid—tight cover which can be used to form the electrical connections between the cells 14 and between cells 14 and the battery terminals 27 and 29. Container cover 22 is shown in detail in Figs. 5—7, and a mold 60 for forming cover 22 is shown in Figs. 8 and 9. Mold 60 forms a part of a conventional screw type injection molding machine (not shown) which comprises a horizontal rotary table (not shown) to facilitate the loading of inserts 50, 52 and 54 into mold 60. In forming cover 22, inserts 50, 52 and 54 are placed in slots 62 in mold 60 with portions contained * in the slots 62 which will extend from the completed cover 22. For clarity, only inserts 50 and 52 are shown in Figs. 8 and 9, it being understood that another insert 50 and another insert 54 would be placed in the mold 60 in the actual molding of a cover 22. It is essential that the metal inserts 50, 52 and 54 be heated to a temperature sufficient to activate chemical bonding between the plastic material and inserts 50, 52 and 54. The inserts 50, 52 and 54 are heated in mold 60 by gas jets 66 to ' a temperature of at least 400°F. Jets 66 can be fueled by butane, but preferably the jets 66 are fueled by hydrogen. After the heating of inserts 50, 52 and 54, jets 66 are moved away, and a mold cover (no ' shown) is moved into place. Plastic material, at a pressure of between 10,000 and 20,000 psi and a temperature between about 375°F and about 475°F, is injected into the mold 60 to form cover 22. After a curing time of about five seconds, cover 22 is removed from the mold. The entire molding operation can be completed ' in about 20 seconds, including the curing time. It is important that a strong bond be formed between the inserts 50, 52 and 54, and the plastic material of cover 22. It has been found that an excellent bond is obtained by using chemically modified polyolefins as the plastic material. A preferred plastic material for forming cover 22 is Polybond ™ 1016 chemically modified polyolefin which is a thermoplastic propylene—ethylene elastomer—acrylic acid terpolymer and is sold by B. P. Performance Polymers Inc., Hackettstown, N.J.; also suitable is Polybond ™ 1001 chemically modified polyolefin. A preferred material for inserts 50, 52 and 54, is stainless steel, preferably type 304. Cover 22 can also be° formed from Plexar m 2511 chemically modified polyolefin, sold by Norche Co. Inserts 50, 52 and 54 can also be made from aluminum and from copper. Terminal plate 26 is formed by injection molding from a material such as polypropylene. Battery terminals 27 and 29 extend through plate 26 and are fixed thereto by, for example, riveting. In the assembly of battery 10, cover 22 is positioned over container 12 and the anode terminal 40 and the cathode terminal 42 in each cell are joined to the appropriate insert 50, 52 and 54, by spot welding. In the lithium-MnO- battery described herein, each of the cells 14 produces 3V, and the cells 14 are connected in series to form a 9V battery. When the electrical connections have been made, cover 22 is ultrasonically welded to container 12. Electrolyte is then added into each of the cells 14 through openings 70 (Fig. 2) in a bottom wall 72 of container 12. Openings 70 are closed by plastic plugs 74 which are ultrasonically welded to wall 72. Preferred electrolytes for battery 12 are electrolytes comprising, for example, a solvent mixture of a propylene carbonate and dimethoxyethane used with a lithium salt such as lithium tetrafluoro— borate, or a solvent mixture of butyrolactone and di— methoxyethane used with a lithium salt such as lith¬ ium tetrafluoroborate (LiBF. ) or lithium trifluoro— methanesulfonate (LiCF-SO ). One suitable elec¬ trolyte would be an electrolyte containing 1M LiBF in a solvent mixture of 4—butyrolactone and dimeth— oxyethane. Another suitable electrolyte would contain 1M LiCF.,S0 3 in a solvent mixture of 4—butyrolactone and dimethoxyethane. After the electrolyte has been added to each of the cells 14, terminal plate 26 is electrically connected to cover 22 by welding leads (not shown) from terminals 27 and 29 to inserts 52 and 54 respectively. In a final step, terminal plate 26 is ultrasonically welded to cover 22.

Claims: CLAIMS 1. A method of making a battery, said method comprising the steps of: forming a container having a plurality of cavities therein; injecting heated plastic into a mold having heated electrically—conductive inserts therein to form a battery cover; inserting electrodes into each of said cavities to form a plurality of cells, said electrodes being arranged in said cavities such that terminals thereof are located adjacent an opening of each of the cavities; joining said terminals of each cell to said conductive inserts to form electrical connections between said cells and between battery terminals on said battery cover; and ultrasonically welding said battery cover to said container. 2. A method, as defined in claim 1, wherein said battery cover includes a container cover and a terminal plate, and said method includes the step of connecting said inserts to terminals on said terminal plate. 3. A method * , as defined in claim 2, and further including the step of ultrasonically welding said terminal plate to said container cover. 4. A method, as defined in claim 2, wherein said container cover is formed from a chemically modified polyolefin. 5. A method, as defined in claim 4, wherein said container cover is formed from Polybond m 1016 chemically modified polyolefin. 6. A method, as defined in claim 4, wherein said inserts are stainless steel. 7. A method, as defined in claim 1, and further including the steps of adding an electrolyte through an opening in a bottom wall of said container, closing said opening with a plug, and ultrasonically welding said plug to said bottom wall to seal said opening. 8. A method, as defined in claim 1, wherein said heated electrically—conductive inserts are at a temperature of about 400°F when said heated plastic is injected into said mold. 9. A method, as defined in claim 8, wherein said heated plastic is between about 375°F and about 475°F when it is injected into said mold, and said container is formed from a polypropylene having a reinforcing filler therein. 10. A method of making a cover from a plastic for use in a battery, said method comprising the steps of: placing electrically conductive inserts in grooves in a mold such that first portions of said inserts are exposed and second portions are contained in said grooves; heating said inserts to a temperature sufficient to activate chemical bonding between said inserts and the plastic; and injecting heated plastic into said mold to form a cover in which the first portions of said inserts are embedded in the plastic and bonded thereto and said second portions are exposed. 11. A method, as defined in claim 10, wherein said heating step is performed with a gas flame. 12. A method, as defined in claim 10, wherein said inserts are stainless steel. 13. A method, as defined in claim 10, wherein said plastic is a chemically modified polyolefin. 14. A method, as defined in claim -10, wherein said plastic is Polybond m 1016 chemically modified polyolefin. 15. A method, as defined in claim 10, wherein said inserts are at a temperature of about 400°F when said heated plastic is injected into said mold. 16. A method, as defined in claim 10, wherein said plastic is between about 375°F and about 475°F when it is injected into said mold. 17. A method of making a battery, said method comprising the steps of: forming a container with a plurality of cavities therein, each of said cavities having an opening for receiving electrodes, said container having walls defining said cavities, and said walls having edges adjacent said openings; forming a battery cover having conductive inserts molded therein, said cover having ridges formed on one surface thereof; inserting electrodes in each of said cavities to form a plurality of cells, said electrodes being arranged in a cavity such that terminals thereof are located adjacent the opening of the cavity; joining said terminals of each cell to said conductive inserts to form electrical connections between said cells and between said cells and battery terminals on said battery cover; placing said cover on said container with said ridges in contact with said edges; and ultrasonically welding said battery cover to said container to fuse said cover and walls and form hermetically—sealed cells in each of said cavities.

Inventors: CATALDI RICHARD THOMAS, CLARK PETER STUYVESANT, CATALDI, RICHARD, THOMAS, CLARK, PETER, STUYVESANT
Applicants: EASTMAN KODAK CO, EASTMAN KODAK COMPANY
Application year: 1987
Main classification: H01M2
IPC codes: H01M2