Abstract:
A cell having a separator with pores prevents short-circuiting of the anode and cathode while increasing the internal space of the cell, increasing the injection volume of electrolyte, and decreasing internal gas pressures for longer durability.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to a group of winding electrodes, and more particularly, to a novel separator with high durability and capacity, and low internal pressure for use in a cylindrical cell or a condenser. 
     2. Description of the Related Art 
     A group of winding electrodes, such as a cylindrical cell or a condenser, has a separator to prevent a short-circuit between the cathode and the anode. The present invention relates to a technology for a group of winding electrodes having a cathode, anode and separator. A cylindrical cell, especially a cylindrical nickel-hydrogen cell, is described as an example. 
     More and more portable electronic devices, such as a camera, a camcorder, a portable CDP, a radio, a cassette, a notebook computer, a pager and a cellular phone, etc., require a cell having higher capacity and longer durability. 
     In general, a cell is a device that converts chemical energy into electric energy by means of contact potential difference and many kinds of such cells are conventionally known to those skilled in the art. Electrochemical cells and batteries are technologically identified as nonchargeable primary cells, rechargeable secondary cells, fuel cells that convert combustion heat into electric energy or solar cells that convert light energy into electric energy. Electrochemical cells and batteries are classified by the composition of electrolyte and the shape of the cells and batteries. The composition of electrolyte is alkaline, solid or nonaqueous cells and the shape is cylindrical, button or coin type. 
     In these kinds of cells, a cylindrical cell (jelly-roll type) discharges current and is composed of a cathode, an anode, a separator to prevent a short-circuit between the cathode and the anode, an electrolyte, a positive terminal, and a negative terminal. The structure of a nickel-hydrogen cell is illustrated in FIG. 8. The cylindrical nickel-hydrogen cell is composed of a cathode (13) coated with Ni(OH) 2  as a positive active material, an anode (15) of hydrogenated alloy coated with a negative active material which is mainly composed of LaNi 5 , MmNi 5 , Ti--Fe or Ti--Ni alloy, a separator (17) which is made of a nonwoven fabric and a cellophane tape to prevent a short-circuit between the cathode (13) and the anode (15), a cap (19) as a positive terminal, a case (12) as a negative terminal a gasket (21), a safety vent (23), a cover plate (25), an insulating ring (27), and an insulating plate (29). 
     The process for fabricating a cylindrical nickel-hydrogen cell is as follows. First, the cathode is manufactured by coating a slurry positive active material on a metallic support and then drying and rolling the coated metallic support. The anode is manufactured by coating a slurry negative active material on a metallic support and then drying and rolling the coated metallic support. After that, a separator is laid between the cathode and the anode, and is wound. The wound assembly comprising the electrodes and separator is inserted into the can. After that, an electrolyte is poured into the can and a cap assembly is mounted in the mouth of the upper part. 
     A detailed description of the charge and the discharge reaction of the cylindrical nickel-hydrogen cell manufactured according to the above method is as follows. 
     A hydrogenated alloy is used as a negative active material, nickel hydroxide is used as a positive active material and potassium hydroxide (KOH) aqueous solution is used as an electrolyte. The hydrogenated alloy stores hydrogen ions produced by cleavage of water in the electrolyte during the charging process, and releases hydrogen ions into the electrolyte during the discharging process. The charge and discharge reactions are as follows. ##STR1## 
     In the above reactions, M is a hydrogenated alloy that can absorb and emit hydrogen ions, identified as an AB 5  group that is made of rare earth elements or an AB 2  group that is made of Ti, Zr, V, etc. According to the above reaction, a cell performs a charge and discharge more than hundreds of times. 
     In the process for fabricating the cylindrical nickel-hydrogen cell with the above function and structure, as shown in FIG. 1, a cathode (13) and an anode (15) are placed on the opposite sides of a separator (17) to wind by using a mandrel around the center of the winding axis (11). But the separator, used to prevent a short-circuit between the cathode and the anode, takes up a lot of space in the can, and decreases the internal space in the cell for the injection of electrolyte and, therefore, reduces the capacity of cell. In addition, when the cathode (13), the anode (15) and the separator (17) are wound in the above way, the separator can rip, thus allowing the cathode and anode to short. 
     As shown FIG. 2, a technique of using an additional separator (31) covering the initial part of the cathode (13) to the initial part of the anode (15) is developed to prevent short-circuiting due to cracking of the separator (17). Although short-circuiting may be prevented, the additional separator (31) reduces the capacity of the cell because of the additional space it occupies. 
     As shown FIG. 3, an alternative approach is known wherein an additional separator (41) is positioned to cover from the winding axis to the initial part of the cathode (13). This approach solves the problem of decreased capacity of a cell, however, this approach still has the problem that the capacity of a cell is not increased that much because of the limits in decreasing the volume of separator. 
     The foregoing defect occurs in all kinds of groups of winding electrodes including a cylindrical cell and a cylindrical condenser as well as the foregoing cylindrical nickel-hydrogen cell. 
     SUMMARY OF THE INVENTION 
     To overcome the problems of the conventional arts, an object of the present invention is to provide a group of winding electrodes comprising a cathode, a positive terminal linked to the cathode, an anode, a negative terminal linked to the anode, a separator placed in between the cathode and anode, and an electrolyte characterized in that the separator has a plurality of pores in the region which is not overlapped by the cathode or anode. 
     Preferably, the group of winding electrodes further comprises an additional separator on one side of the separator. 
     Preferably, the additional separator extends from the initial part of the cathode to the initial part of the anode. Preferably, the additional separator has a plurality of pores in the region which is not overlapped by the cathode or the anode. 
     Preferably, the additional separator extends from the initial part of the cathode to the winding axis. Preferably, the additional separator has a plurality of pores in the region which is not overlapped by the cathode or anode. 
     Preferably, the pore is one or more shapes, including a circle, a triangle, a square, a hexagon and an octagon. 
     Preferably, the group of winding electrodes is a cylindrical cell or a cylindrical condenser. 
     Alternatively, the group of winding electrodes is preferably a cylindrical nickel-hydrogen cell. 
     Additional objects, advantages and novel features of the invention will be set forth in part in the description which follows, and in part will become apparent to those skilled in the art upon examination of the following and may be learned by practice of the invention. The object and advantages of the invention may be realized and attained by means of the instrumentalities and combinations particularly pointed out in the appended claims. 
    
    
     BRIEF DESCRIPTION OF THE DRAWING IN THE DRAWING: 
     FIG. 1 is a schematic diagram showing a conventional cathode, anode and parts of a separator before winding. 
     FIG. 2 is an another schematic diagram showing a conventional cathode, anode, parts of a separator and additional separator before winding. 
     FIG. 3 is the third schematic diagram showing a conventional cathode, anode, parts of a separator and additional separator before winding. 
     FIG. 4 is a schematic diagram showing a cathode, an anode and parts of a separator before winding according to a first embodiment of the present invention. 
     FIG. 5 is a schematic diagram showing a cathode, an anode, parts of a separator and additional separator before winding according to a second embodiment of the present invention. 
     FIG. 6 is a schematic diagram showing a cathode, an anode, parts of a separator and additional separator before winding according to a third embodiment of the present invention. 
     FIG. 7 is an illustration of the many shapes, numbers, and placing of pores in a separator of the present invention. 
     FIG. 8 is an illustration of a structure of a cylindrical cell. 
     In the following detailed description, only the preferred embodiment of the invention has been shown and described, simply by way of illustration of the best mode contemplated by the inventor(s) of carrying out the invention. As will be realized, the invention is capable of modification in various alternative respects, all without departing from the invention. Accordingly, the drawing and description are to be regarded as illustrative in nature, and not as restrictive. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     EXAMPLE 1 
     As shown in FIG. 4, a cathode (13) having a size of 114×35×0.73 mm and an anode (15) having a size of 149×35×0.40 mm were arranged on opposing sides of a separator (17) having a size of 263×38×0.15 mm and centered around the winding axis (11). A plurality of pores having a radius of 1 mm were established in a region of the separator that is not overlapped by the cathode and the anode. The cathode (13), the anode (15) and the separator (17) were wounded around the center of the winding axis and inserted into a can. Electrolyte injection, assembling and formation were performed to is fabricate a cell. 
     EXAMPLE 2 
     As shown in FIG. 5, a cathode (13) having a size of 114×35×0.73 mm and an anode (15) having a size of 149×35×0.40 mm were arranged on opposing sides of a separator (17) having a size of 263×38×0.15 mm and centered around the winding axis (11). An additional separator (31) having a size of 40×38×0.15 mm, enough to cover the initial parts of the cathode (13) and the anode (15), was placed on one side of the separator (17) with the cathode (13). A plurality of pores having a radius of 1 mm were established in a region of the separator (17) and the additional separator (31) that is not overlapped by the cathode (13) and the anode (15). After winding the cathode (13), the anode (15), the separator (17) and the additional separator (31) around the winding axis (11), the wound assembly was inserted into a can. Electrolyte injection, assembling and formation were performed to fabricate a cell. 
     EXAMPLE 3 
     As shown in FIG. 6, a cathode (13) having a size of 114×35×0.73 mm and an anode (15) having a size of 149×35×0.40 mm were arranged on opposing sides of a separator (17) having a size of 263×38×0.15 mm and centered around the winding axis (11). An additional separator (41) having a size of 26×38×0.15 mm, enough to cover from the initial part of the cathode (13) to the winding axis (11), was placed on one side of separator (17) with the cathode (13). A plurality of pores having a radius of 1 mm were established in a region of the separator (17) and the additional separator (41) that is not overlapped by the cathode (13) and the anode (15). After winding the cathode (13), the anode (15), the separator (17) and the additional separator (41) around the winding axis (11), the wound assembly was inserted into a can. Electrolyte injection, assembling and formation were performed to fabricate a cell. 
     COMPARATIVE EXAMPLE 1 
     As shown in FIG. 1, a cathode(13) having a size of 114×35×0.73 mm and an anode (15) having a size of 149×35×0.40 mm were arranged on opposing sides of a separator (17) having a size of 263×38×0.15 mm and centered around the winding axis (11). After winding the cathode (13), the anode (15) and the separator (17) around the winding axis (11), the wound assembly was inserted into a can. Electrolyte injection, assembling and formation were performed to fabricate a cell. 
     COMPARATIVE EXAMPLE 2 
     As shown in FIG. 2, a cathode (13) having a size of 114×35×0.73 mm and an anode (15) having a size of 149×35×0.40 mm were arranged on opposing sides of a separator (17) having a size of 263×38×0.15 mm and centered around the winding axis (11). An additional separator (31) having a size of 40×38×0.15 mm, enough to cover from the initial parts of the cathode (13) and the anode (15), was placed on one side of the separator (17) with cathode (13). After winding the cathode (13), the anode (15), the separator (17) and the additional separator (31) around the winding axis (11), the wound assembly was inserted into a can. Electrolyte injection, assembling and formation were performed to fabricate a cell. 
     COMPARATIVE EXAMPLE 3 
     As shown in FIG. 3, a cathode (13) having a size of 114×35×0.73 mm and an anode (15) having a size of 149×35×0.40 mm were arranged on opposing sides of a separator (17) having a size of 263×38×0.15 mm and centered around the winding axis (11). An additional separator (41) having a size of 26×38×0.15 mm, enough to cover from the initial parts of the cathode (13) to the winding axis (11), was placed on one side of the separator (17) with the cathode (13). After winding the cathode (13), the anode (15), the separator (17) and the additional separator (41) around the winding axis (11), the wound assembly was inserted into a can. Electrolyte injection, assembling and formation were performed to fabricate a cell. 
     The following table shows the results of measuring the volume decrease of a separator, injection volume of an electrolyte, internal pressure, and durability according to the above examples and comparative examples. 
     
                       (TABLE)______________________________________          Injection   Internal          volume of an                      pressure DurabilityVolume (mm.sup.3)          electrolyte (g)                      (Kg/cm.sup.2)                               (cycle)______________________________________Example 1   1470       3.4         10     350Example 2   1665       3.4         10     350Example 3   1601       3.4         10     350Comparative   1500       3.2         10     300Example 1comparative   1727       3.2         10     300Example 2Comparative   1647       3.2         10     300Example 3______________________________________ 
    
     As shown in the above table, the volume of the cell with a separator having pores according to examples of the present invention is decreased by a maximum of 7% in comparison with a cell with a separator having no pores according to the comparative examples. Therefore, the internal space of the cell is increased by a maximum of 33% on the basis of the injection volume of the electrolyte. The larger internal space prevents increasing of internal pressure of produced gas. 
     As shown above, the quality of the cell having a separator with pores according to the present invention is excellent because of the increased internal space, increased injection volume of an electrolyte, lower internal gas pressure and much higher durability than that of a conventional cell. 
     As shown FIG. 7, a separator according to the present invention can have pores of one or more various shapes and placement methods. The various shapes of pores are: a circle, a triangle, a square, a hexagon, and an octagon, etc. 
     As shown above, a separator having pores according to the present invention prevents a short-circuit, increases the internal space of the cell, increases the injection volume of an electrolyte and decreases internal gas pressure to have longer durability. The effect of the present invention on a group of winding electrodes is not limited to the cylindrical nickel-hydrogen cell but also can be applied to a cylindrical cell or condenser with the same structure as the cylindrical nickel-hydrogen cell. 
     In this disclosure, there is shown and described only the preferred embodiment of the invention, but, as aforementioned, it is to be understood that the invention is capable of use in various other combination and environments and is capable of changes or modification within the scope of the inventive concepts as expressed herein.