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Process-for-making-laminar-batteries

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Process for making laminar batteries

Details

Inventors: Plasse, Paul A.;
Assignee: Polaroid Corporation (Cambridge, MA)
Primary Examiner: Lefevour; Charles F.
Assistant Examiner:
Attorney, Agent or Firm: Maccarone; Gaetano D.

Laminar electrical cells and batteries, each cell of which comprises a first electrode formed as a porous layer of electrochemically active particles on an electrically conductive, electrochemically inactive substrate coextensive with the particle layer. The electrochemically inactive substrate is adhered around its periphery to the borders of an aperture in an electrically insulating frame. A separator for each cell overlies the active particle layer of the first electrode and has borders extending beyond the borders of the first electrode and within the borders of the insulating frame. A second electrode for each cell comprises a slurry of electrochemically active particles in contact with the other side of the separator. Methods of making the above cells and batteries from elongated webs of electrically insulating ones of the constituent materials of the cells.

DETAILED DESCRIPTION Having thus described the invention, what is claimed is: 1.
The process of making laminar cells, comprising the steps of perforating a first elongated web of liquid impervious, electrically nonconducting thermoplastic material with a spaced rectangular array of apertures arranged in rows across the direction of elongation of said web and in columns parallel to the direction of elongation of said web, adding patches of electrically conductive material each comprising a sheet of conductive plastic adhered to a coterminous layer of electrode particles in a binder to a first side of said first web with the conductive plastic side of each patch in contact with the borders of a different one of said apertures to form a spaced rectangular array of said patches on said first web, adhering a piece of separator material to said first web over each of said patches on said first side of said first web, placing spaced elongated strips of metal on said first web on a second side of said first web opposite said first side, said metal strips being aligned with and each overlying a different one of said columns, laminating said strips to contiguous portions of said first web and to portions of the conductive plastic sides of said patches within said apertures, advancing said first web into registry with a second web of nonconducting material while advancing said second web at constant speed, severing strips from said first web between said rows and transferring said severed strips to said second web in spaced parallel rows each perpendicular to the direction of advance of said second web, extruding deposits of slurry electrode material onto each of said pieces of separator material, placing a piece of conductive terminal material comprising a layer of metal adhered to a layer of conductive plastic over each deposit of slurry electrode material with the conductive plastic layer of each terminal piece in contact with the slurry, each piece of said terminal material having borders extending beyond the borders of said slurry deposits and the underlying electrode patches and overlying confronting regions of said first web but spaced from each adjacent terminal piece, and adhering the borders of said terminal pieces to said first web to form sealed cells

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