Title of Invention

A THREE-DIMENSIONAL BATTERY WITH AN ELECTRODE STRUCTURE AND A METHOD FOR PRODUCING THE SAME

Abstract When producing an electrode for use in a three- dimensional battery, an active material (12, 14) is combined with at least one of a separator (10), a dividing wall (16), and a current collector (18, 20) for simultaneous formation. Both the dividing wall (16) and the current collector (18, 20) are planar or are so formed as to have projected portions in needle, plate, wave, particle, or the like form. Both the dividing wall (16) and the current collector (18, 20) may be provided with a cooling structure. As an additional current collector, an ion permeable current collector (22), which has voids therein, permits passage of ions, and exhibits electrical conductive properties, is provided.
Full Text DESCRIPTION
A THREE - DIMENSIONAL BATTERY WITH AN ELECTRODE
STRUCTURE, AND A METHOD FOR PRODUCING THE SAME
TECHNICAL FIELD
This invention relates to an electrode structure of a three-dimensional
battery constructed by the filling of an active material in powder, particle, plate and
the like form and to its producing method. The present invention further relates to a
high power type three-dimensional battery which is based on a bellows-shaped unit
and which is capable of increasing its size easily.
BACKGROUND ART
The present invention relates to a three-dimensional battery. The
problems to be solved by the present invention is classified into the following
problems in view of prior arts.
A first problem is to provide a three-dimensional battery which requires a
less number of component parts than conventional and which reduces assembly
time and assembly cost. Additionally, the first problem is to provide an electrode
structure of the three-dimensional battery and a method for producing an electrode
material of the three-dimensional battery. Furthermore, the first problem is to
provide, at low cost, a three-dimensional battery which has a large current collecting
area and which is capable of charging and discharging at high rate.
A second problem is to provide a high power type three-dimensional
battery capable of increasing its size easily and generating high output power
without undergoing a drop in performance due to the increase in size.
Hereinafter, the first and second probelems will be discussed in order by
comparison with prior arts.'
1. PRIOR ART AND FIRST PROBLEM
Japanese Patent Publication No. 3051401 discloses a so-called
three-dimensional battery comprising an active material in powder or particle form.

Additionally, International Publication WO 00/59062 discloses a layered
three-dimensional battery. Furthermore, a three-dimensional battery in which a
particulate active material is filled as a fixed layer is disclosed in Japanese Patent
Provisional Publication No 2002-141101 and Japanese Patent Provisional
Publication No. 2002-141104. When producing such three-dimensional battery, a
separator and a current collector have been preassembled in a given order to
complete a cell and, then, the cell has been filled with an active material in powder,
particle or the like form.
However, when producing a three-dimensional battery by the use of a
method in which a cell, into which a separator and a current collector have been
preassembled, is filled with an active material, there is a possibility that it becomes
difficult to carry out the filling of a cell with an active material. Besides, when
assembling component parts necessary for the assembly of a battery in order, the
number of component parts, such as a current collector, a cell, an active material, a
separator and the like, increases, therefore making the work of assembly extremely
complicated. Accordingly, assembly time and assembly cost will increase.
In addition to the above, the current collecting area of a three-dimensional
battery that employs only a planar current collector is relatively narrow, therefore
presenting the problem that there occurs a drop in battery performance when
carrying out charging and discharging at high rate (high current charging and
discharging).
In view of the above-described drawbacks, the present invention has been
devised. Accordingly, the first problem to be solved by the present invention is to
provide a three-dimensional battery, an electrode structue of the three-dimensional
battery, and a method for producing an electrode material of the three-dimensional
battery. More specifically, by virtue of the present invention, the number of
component parts required at the time of battery assembly, the assembly time, and
the assembly costs are all reduced by simultaneous formation by combination of an
active material with at least one of a separator, a dividing wall, and a current
collector when producing the electrode of the three-dimensional battery.
Additionally, the first problem to be solved by the present invention is to
provide an electrdoe structure of the three-dimensional battery and a method for

producing an electrode material of the three-dimensional battery. More specifically,
by virtue of the present invention, is achieved the increase in current collecting area
by forming projected portions in needle, plate, wave, particle, or the like form on the
constituent components of the three-dimensional battery such as a dividing wall and
a current collector, thereby making it possible to carry out charging and discharging
at high rate (high current charging and discharging).
Finally, the first problem to be solved by the present invention is to provide
an electrode structue of the three-dimensional battery and a method for producing
an electrode material of the three-dimensional battery. More specifically, by virtue
of the present invention, it becomes possible to provide an increased current
collecting area by the use of an ion permeable current collector having therein
voids, thereby making it possible to carry out charging and discharging at high rate
(high current charging and discharging).
2. PRIOR ART AND SECOND PROBLEM
As described above, Japanese Patent Publication No. 3052401 discloses
a so-called three-dimensional battery comprising a powdered or particulate active
material. International Publication WO 00/59062 discloses a layered
three-dimensional battery. A three-dimensional battery in which a particulate active
material is filled for formation of a fixed layer is disclosed in Japanese Patent
Provisional Publication No.2002-141101 and Japanese Patent Provisional
Publication No. 2002-141104.
In a nickel-hydrogen secondary battery of the conventional structure, nickel
hydroxide which serves as a cathode of the nickel-hydrogen secondary battery does
not have electrical conductivity. To cope with this, the surface of the nickel
hydroxide is coated with a cobalt compound which is electrically conductivity. This
is filled into a foamed nickel sheet for the purpose of shape support and electrical
conduction. Since it is impossible to achieve adhesive joining of the foamed nickel
sheet and the nickel hydroxide in an alkali electrolytic solution, separation is
prevented by application of physical pressure from the outside. Additionally, in
order to reduce the degree of electrical resistance between the foamed nickel sheet
and the nickel hydroxide, it is required that the foamed nickel sheet be reduced in
thickness. To this end, a foamed nickel sheet having a thickness of about 1.1 mm,

into which paste -like nickel hydroxide has been filled, is so compacted as to have a
thickness of about 0.6 mm. Additionally, in order to obtain smooth ion diffusion, the
distance between the cathode and the anode should be as small as possible.
Therefore, the thickness of battery structure comprising the cathode, the separator
and the anode does not exceed 2 mm.
For the case of nickel-hydrogen secondary batteries of the conventional
structure, there is no other way, indeed, in order to achieve the increase in size
while meeting the above-described requirements, than to increase the area of the
cathode and the anode without changing the thickness of the foamed nickel sheet.
However, there is the limit of increasing the area per sheet. To cope with such
limitation, the number of foamed nickel sheets is increased and multiple foamed
nickel sheets are connected. In this case, welding connection of conducting wires
(nickel plates or the like) is employed as a connecting technique, which, however,
results in the increase in electrical resistance. Accordingly, the performance of the
large-scale battery falls.
Furthermore, in the structure of a conventional dry battery, a
thinly-compacted planar active material sheet, sandwiched in between separators, is
rolled up into a cylindrical form. The rolled-up sheet is filled into a battery cell. For
example, in a nickel-hydrogen secondary battery, a planar active material (a sheet
into which hydrogen-occuluding alloy as an anode has been filled, for the case of
nickel-hydrogen battery) which is in direct contact with a battery cell and which is
the outermost surface, has a large contact area with a current collector (the battery
cell is shared with an anode current collector), and a sheet, into which a cathode
active material (nickel hydroxide) has been filled, is connected by welding to a fine
conducting wire (a nickel plate or the like). Further, it is connected by welding to an
external terminal. The problem arising here is that there are two welds and the
cross sectional area of the conducting wire (nickel plate or the like) establishing
connection between the active material and the external terminal is narrow.
That is, the existence of welds increases electrical resistance, production
cost and manufacturing time. Additionally, since the cross sectional area of the
conducting wire (nickel plate or the like) establishing connection between the active
material and the external terminal is narrow, it is inevitable that both electrical

resistance and heat release value increase when a heavy current flows.
Additionally, in the structure of a conventional industrial battery, for
example, in the case of NiCd secondary battery, thinly-compacted, planar active
material sheets are layered one upon the other so that the cathode, the separator,
the anode, the separator, the cathode in such order, and a fine
conducting wire (nickel plate or the like) is connected to each planar active material
sheet, and a group of the cathodes are connected by welding to an external
terminal while a group of the anodes are connected by welding to an external
terminal. The problem arising here is that electrical resistance, production cost,
and manufacturing time increase because the plural planar active material sheets
are connected by welding to the external terminal.
The performance of single dry battery is satisfactory. However, if plural
dry batteries are connected together in series or parallel when a large capacity
battery is required, the output voltage drops due to the resistance of contact with
external terminals. As a result, the battery becomes poor in performance. On the
other hand, for the case of industrial batteries being originally large in size, they
have problems with their basic structure, in other words there are many welding
points. Accordingly, high-performance batteries are not obtained.
In view of the above-described drawbacks, the present invention has been
devised. Accordingly, the second problem to be solved by the present invention is
to provide a high power type three-dimensional battery capable of increasing its size
easily and generating high output power without undergoing a drop in performance
due to the increase in size, and reducing production cost and manufacturing time.
DISCLOSURE OF THE INVENTION
1. INVENTIONS FOR SOLVING THE FIRST PROBLEM
In order to solve the first problem, the present invention provides a
three-dimensional battery comprising a battery constitution unit having two vessels
connected with a separator interposed therebetween that permits passage of ions
but does not permit passage of electron, a forming product in powder, particle or
plate shape of active material in an electrolytic solution filled in one of the vessels to
discharge the electron, and a forming product in powder, particle or plate shape of

active material in an electrolytic solution filled in the other vessel to absorb the
electron,
the three-dimensional battery having either a configuration which consists
of a single battery unit in which an electrically conductive current collector in contact
with the active material, which does not permit passage of ions, is provided in each
of the two vessels, or
a configuration which consists of plural battery units layered one upon the
other through respective electrically conductive dividing walls which does not permit
passage of ions, in which vessels situated on both ends are each provided with an
electrically conductive current collector in contact with the active material, which
does not permit passage of ions,
wherein the three-dimensional battery has an electrode structure in which
an active material cured by adding an electrically conductive filler and a resin to a
material capable of causing a cell reaction, is so produced as to be formed
integrally with at least any one of the separator, the dividing wall, and the current
collector.
The present invention provides a three-dimensional battery with an
electrode structure comprising a battery constitution unit having two vessels
connected with a separator interposed therebetween, a forming product in powder,
particle or plate shape of active material in an electrolytic solution filled in one of the
vessels to discharge the electron, and a forming product in powder, particle or plate
shape of active material in an electrolytic solution filled in the other vessel to absorb
the electron,
the three-dimensional battery having either a configuration which consists
of a single battery unit in which a current collector in contact with the active material
is provided in each of the two vessels, or
a configuration which consists of plural battery units layered one upon the
other through respective dividing walls, in which vessels situated on both ends are
each provided with a current collector in contact with the active material,
wherein the active material cured by adding an electrically conductive filler
and a resin to a material capable of causing a ceil reaction, is so produced as to be
formed integrally with the separator.

In the above-described constitution, the separator can be made of a
material which undergoes no deterioration such as corrosion in an alkali electrolytic
solution, which has electrical insulation properties, and which permits passage of
ions. For example, as the separator material, a textile or nonwoven cloth made of
any one selected from the group consisting of polytetrafluoroethylene, polyethylene,
nylon, polypropylene and the like, or membrane filter may be used.
Furthermore, the present invention provides a three-dimensional battery
with an electrode structure comprising a battery unit having two vessels
connected with a separator interposed therebetween, a forming product in powder,
particle or plate shape of active material in an electrolytic solution filled in one of the
vessels to discharge the electron, and a forming product in powder, particle or plate
shape of active material in an electrolytic solution filled in the other vessel to absorb
the electron,
the three-dimensional battery having a configuration which consists of
plural battery units layered one upon the other through respective dividing walls, in
which vessels situated on both ends are each provided with a current collector in
contact with the active material,
wherein the active material cured by adding an electrically conductive filler
and a resin to a material capable of causing a cell reaction, is so produced as to be
formed integrally with the dividing wall.
In the above-described constitution, the dividing wall can be made of a
material which undergoes no deterioration such as corrosion in an alkali electrolytic
solution, which does not permit passage of ions, and which has electrical conductive
properties. For example, as the material of the dividing wall, any one selected from
the group consisting of a nickel metal plate, a nickel metal foil, carbon, nickel-plated
iron, nickel-plated stainless steel, nickel-plated carbon and the like may be used.
Additionally, either the dividing wall is planar, or the dividing wall has projected
portions in needle, plate, wave, particle, or the like shape. Furthermore, the
dividing wall provided with a cooling structure which has refrigerant flowing path
inside may be used.
Furthermore, the present invention provides a three-dimensional battery
with an electrode structure comprising a battery unit having two vessels

connected with a separator interposed therebetween, a forming product in powder,
particle or plate shape of active material in an electrolytic solution filled in one of the
vessels to discharge the electron, and a forming product in powder, particle or plate
shape of active material in an electrolytic solution filled in the other vessel to absorb
the electron,
the three-dimensional battery having either a configuration which consists
of a single battery unit in which a current collector in contact with the active material
is provided in each of the two vessels, or
a configuration which consists of plural battery units layered one upon the
other through respective dividing walls, in which vessels situated on both ends are
each provided with a current collector in contact with the active material,
wherein the active material cured by adding an electrically conductive filler
and a resin to a material capable of causing a cell reaction, is so produced as to be
formed integrally with the current collector.
In the above-described arrangement, the current collector can be made of
a material which undergoes no deterioration such as corrosion in an alkali
electrolytic solution, which does not permit passage of ions, and which has electrical
conductive properties. For example, as the material of the current collector, any
one selected from the group consisting of a nickel metal plate, a nickel metal foil,
carbon, nickel-plated iron, nickel-plated stainless steel, nickel-plated carbon and the
like may be used. Furthermore, it is preferable that the current collector in contact
with the active material is provided with an additional ion permeable current
collector which has voids therein, which permits passage of ions, and which has
electrical conductive properties. In addition, the ion permeable current collector can
be made of at least any one selected from the group consisting of a nickel metal
mesh, carbon fibers, a mesh-like body made of nickel-plated iron, nickel-plated
stainless steel and the like, foamed nickel metal, nickel-plated foamed resin,
nickel-plated carbon fibers, nickel-plated inorganic fibers made of silica, alumina and
the like, nickel-plated organic fibers, nickel-plated felt, and nickel-plated foil made of
an inorganic substance such as mica. Furthermore, either the current collector is
planar or the current collector has projected portions in needle, plate, wave, particle,
or the like shape. Additionally, the current collector provided with a cooling

structure which has refrigerant flowing path inside may be employed.
The present invention provides a three-dimensional battery with an
electrode structure which is characterized in that an active material cured by
adding an electrically conductive filler and a resin to a material capable of causing a
cell reaction, is so produced as to be formed integrally with at least any two of a
separator, a dividing wall, and a current collector. In this way, when producing an
electrode for use in a three-dimensional battery, an active material and at least any
two of a separator, a dividing wall, and a current collector are combined together
and formed integrally with one another in one piece.
In the above-described electrode structure, active material of all kinds may
be used as an active material, regardless of the type of battery and regardless of
cathode or anode. For example, as the active material, nickel hydroxide and
hydrogen-occluding alloy which serve as a cathode active material and as an anode
active material respectively in a nickel-hydrogen secondary battery may be used.
In addition to these materials, battery active material known in the art, such as
cadmium hydroxide, lead, lead dioxide, lithium and the like, may be used.
Additionally, general solid substances, such as wood, black lead, carbon, iron ore,
iron carbide, iron sulfide, ion hydroxide, iron oxide, coal, charcoal, sand, gravel,
silica, slag, chaff and the like may be used.
Furthermore, in the above-described electrode structure, an electrically
conductive filler which is added to the active material can be made of either any one
selected from the group consisting of carbon fibers, nickel-plated carbon fibers,
nickel-plated inorganic fibers made of silica, alumina and the like, nickel-plated
organic fibers, nickel-plated foil made of an inorganic substance such as mica,
carbon particles, nickel-plated carbon particles, nickel in fiber shape, nickel particles,
and nickel foil or any combination thereof.
Additionally, a resin which is added to the active material may be selected
from the group consisting of a thermoplastic resin having the softening temperature
of which is up to 120 °C, a resin having the curing temperature of which ranges
from room temperature up to 120 °C, a resin dissolvable in a solvent having the
evaporating temperature of which does not exceed 120 °C, a resin dissolvable in a
water-soluble solvent, and a resin dissolvable in an alcohol-soluble solvent. For

example, in the case where a nickel hydroxide as active material is used, its activity
is lost at temperatures above 130 °C, therefore requiring that various processes be
carried out at temperatures below 130 °C. In addition, since active materials are
used in an alkali electrolyte solution, alkali resistance is needed for the active
materials.
As the thermoplastic resin having a softening temperature of up to 120 °C,
any one selected from the group consisting of polyethylene, polypropylene, and
ethylene-vinyl acetate copolymer may be used. As the resin having a curing
temperature ranging from room temperature up to 120 °C, reaction-curing resin
(e.g., epoxy resin, urethane resin, unsaturated polyester resin and the like),
thermosetting resin (e.g., phenol resin and the like), or the like may be used. As
the resin dissolvable in a solvent having an evaporating temperature that does not
exceed 120 °C, any one of the foregoing thermoplastic resins may be used. The
solvent-soluble resin is dissolved in a solvent, and added to an active material
substance, and the solvent is removed by evaporation, extraction, or the like.
Additionally, as the resin dissolvable in a water-soluble and extractable solvent, any
one selected from the group consisting of polyether sulfone resin (PES),
polystyrene, polysulfone, polyacrylonitrile, polyvinylidene fluoride, polyamide,
polyimide and the like may be used. As the resin dissolvable in an alcohol-soluble
and extractable solvent, any one of acetylcellulose, oxide phenylene ether (PPO), or
the like may be used.
In the above-described electrode structure, the active material may be in
any one of powder, particle, plate, scale, cylindrical rod, polygonal cylindrical rod,
sphere, dice, cube, amorphous particle shape and the like shape. Additionally, the
surface of the active material is coated either with a nickel-plated layer or with at
least any one selected from the group consisting of carbon fibers, nickel-plated
carbon fibers, nickel-plated organic fibers, nickel-plated inorganic fibers made of
silica, alumina and the like, nickel-plated foil made of inorganic substance such as
mica, carbon powder, nickel-plated carbon powder, nickel in fiber form, and nickel
particle and nickel foil.
The present invention provides a method of producing a three-dimensional
battery with an electrode structure which is characterized in that, when

producing an electrode for use in a three-dimensional battery having the
above-described constitution, an active material cured by adding an electrically
conductive filler and a resin to a material capable of causing a cell reaction, and a
separator are combined together and formed integrally with each other in one piece.
In such a method, the separator can be made of a material which undergoes no
deterioration such as corrosion in an alkali electrolytic solution, which has electrical
insulation properties, and which permits passage of ions and wherein the separator
material is a textile or nonwoven cloth made of any one selected from the group
consisting of polytetrafluoroethylene, polyethylene, polypropylene, nylon and the
like, or membrane filter.
The present invention provides a method of producing a three-dimensional
battery with an electrode structure which is characterized in that, when
producing an electrode for use in a three-dimensional battery having the
above-described constitution, an active material cured by adding an electrically
conductive filler and a resin to a material capable of causing a cell reaction, and a
dividing wall are combined together and formed integrally with each other in one
piece. In such a method, the dividing wall can be made of a material which
undergoes no deterioration such as corrosion in an alkali electrolytic solution, which
does not permit passage of ions, and which has electrical conductive properties.
The dividing wall material is selected from the group consisting of a nickel metal
plate, a nickel metal foil, carbon, nickel-plated iron, nickel-plated stainless steel,
nickel-plated carbon and the like. Additionally, preferably the dividing wall is
provided with projected portions in needle, plate, wave, particle or the like shape in
order to obtain a greater current collecting area.
The present invention provides a method of producing a three-dimensional
battery with an electrode structure which is characterized in that, when
producing an electrode for use in a three-dimensional battery having the
above-described constitution, an active material cured by adding an electrically
conductive filler and a resin to a material capable of causing a cell reaction, and a
current collector are combined together and formed integrally with each other in one
piece. In such a method, the current collector can be made of a material which
undergoes no deterioration such as corrosion in an alkali electrolytic solution, which

does not permit passage of ions, and which has electrical conductive properties.
The current collector material is selected from the group consisting of a nickel metal
plate, a nickel metal foil, carbon, nickel-plated iron, nickel-plated stainless steel,
nickel-plated carbon and the like. Preferably the current collector in contact with
the active material is provided with an additional ion permeable current collector
which has voids therein, which permits passage of ions, and which has electrical
conductive properties, in order to obtain a greater current collecting area. The ion
permeable current collector can be made of any one of a nickel metal mesh, carbon
fibers, a mesh-like body made of nickel-plated iron, nickel-plated stainless steel and
the like, foamed nickel metal, nickel-plated foamed resin, nickel-plated carbon fibers,
nickel-plated inorganic fibers made of silica, alumina and the like, nickel-plated
organic fibers, nickel-plated felt, and nickel-plated foil made of an inorganic
substance such as mica. Additionally, preferably the current collector is provided
with projected portions in needle, plate, wave, particle or the like shape in order to
obtain a greater current collecting area.
The present invention provides a method of producing a three-dimensional
battery with an electrode structure which is characterized in that, when
producing an electrode for use in a three-dimensional battery having the
above-described constitution, an active material cured by adding an electrically
conductive filler and a resin to a material capable of causing a cell reaction, and at
least any two of a separator, a dividing wall, and a current collector are combined
together and formed integrally with one another in one piece.
At the time when combining an active material with a separator, a dividing
wall, and a current collector to form them into one piece, pressurized forming and/or
forming by a resin mixed with an electrically conductive filler may be carried out.
2. INVENTIONS FOR SOLVING THE SECOND PROBLEM
In order to solve the second problem, the present invention provides a
high power type three-dimensional battery wherein:
a bellows-shaped separator is so located between a cathode current
collector and an anode current collector which are disposed face to face with each
other as to come close to the current collectors alternately,
either powder or a forming product of a cathode active material is filled,

together with an electrolytic solution, in a space defined by the bellows-shaped
separator and the cathode current collector,
either powder or a forming product of an anode active material is filled,
together with an electrolytic solution, in a space defined by the bellows-shaped
separator and the anode current collector, and
the cathode active materials and the anode active materials are filled
alternately, facing each other across the separator.
In the above-described constitution, a plurality of units, each comprising at
least one cathode active material and at least one anode active material which are
filled alternately facing each other across a bellows-shaped separator, are mounted
in parallel in a vessel defined between the cathode current collector and the anode
current collector, for providing high output powers.
Furthermore, it is possible to provide high voltages by layering in series
batteries, in each of which cathode active materials and anode active materials are
so mounted into being bellows-shaped as to face each other across a separator,
one upon the other through respective dividing walls.
Furthermore, it is possible to provide high voltages by layering in series
batteries, in each of which a plurality of units described above are mounted in
parallel, one upon the other through respective dividing walls.
Furthermore, in the above-described constitution, a shape of the cathode
active materials and anode active materials to be filled is any one of powders, a
forming product in particle, plate, block or rod form, secondary formed particles in
block or plate form, or pasty powders or particles. When used in pasty form,
polyvinyl alcohol (PVA) or the like may be used as a solvent for the dispersion of
powders and the like.
Additionally, in the above-described constitution, preferably an ion
permeable current collector is mounted in given parts (a surface portion and an
inner portion) of each of the active materials which are so mounted as to face each
other across the bellows-shaped separator.
Furthermore, in the above-described constitution, preferably a given
surface of each of the active materials which are so mounted as to face each other
across the bellows-shaped separator is coated with an ion permeable current

collector. In this case, one prepared by coating an active material surface with an
ion permeable current collector so that they are formed integrally in one piece may
be used.
The ion permeable current collector can be made of a material which has
voids therein, which permits passage of ions, and which has electrical conductive
properties. For example, the ion permeable current collector material is selected
from the group consisting of foamed nickel metal, a nickel metal mesh, nickel-plated
punching metal, metal such as expanded metal and the like, nickel-plated foamed
resin such as urethane and the like, nickel-plated porous material made of
polyethylene, polypropylene, nylon, cotton, carbon fibers and the like, nickel-plated
inorganic fibers made of silica, alumina and the like, nickel-plated organic fibers,
nickel-plated felt, and nickel-plated foil made of an inorganic substance such as
mica.
The separator can be made of a material which undergoes no
deterioration such as corrosion in an alkali electrolytic solution, which has electrical
insulation properties, and which permits passage of ions. For example, as the
separator material, a textile or nonwoven cloth made of any one selected from the
group consisting of polytetrafluoroethylene, polyethylene, polypropylene, nylon and
the like or membrane filter may be used.
The cathode current collectors and anode current collectors are each
made of a material which undergoes no deterioration such as corrosion in an alkali
electrolytic solution, which does not permit passage of ions, and which has
electrical conductive properties. For example, as each material of the cathode
current collectors and anode current collectors, any one selected from the group
consisting of a nickel metal plate, a nickel metal foil, carbon, nickel-plated iron,
nickel-plated stainless steel, nickel-plated carbon and the like may be used.
The dividing wall can be made of a material which undergoes no
deterioration such as corrosion in an alkali electrolytic solution, which does not
permit passage of ions, and which has electrical conductive properties. For
example, as the dividing wall material, any one selected from the group consisting
of a nickel metal plate, a nickel metal foil, carbon, nickel-plated iron, nickel-plated
stainless steel, nickel-plated carbon and the like may be used.

As the active material, one cured by addition of an electrically conductive
filler and a resin to a material capable of causing a cell reaction may be used.
As the active material, active material of all kinds may be used, regardless
of the type of battery and regardless of cathode or anode. For example, nickel
hydroxide and hydrogen-occluding alloy which serve as a cathode active material
and as an anode active material respectively in a nickel-hydrogen secondary battery
may be used.
As the electrically conductive filler, either any one selected from the group
consisting of carbon fibers, nickel-plated carbon fibers, carbon particles,
nickel-plated carbon particles, nickel-plated organic fibers, nickel-plated inorganic
fibers made of silica, alumina and the like, nickel-plated foil made of an inorganic
substance such as mica, nickel in fiber form, nickel particles, and nickel foil or any
combination thereof may be used.
Additionally, the resin which is added to the active material may be
selected from the group consisting of a thermoplastic resin having the softening
temperature of which is up to 120 °C, a resin having the curing temperature of
which ranges from room temperature up to 120 °C, a resin dissolvable in a solvent
having the evaporating temperature of which does not exceed 120 °C, a resin
dissolvable in a water-soluble solvent, and a resin dissolvable in an alcohol-soluble
solvent. For example, in the case where a nickel hydroxide as active material is
used, its activity is lost at temperatures above 130 °C, therefore requiring that
various processes be carried out at temperatures below 130 °C. In addition, since
active materials are used in an alkali electrolyte solution, alkali resistance is needed
for the active materials.
As the thermoplastic resin having a softening temperature of up to 120 °C,
any one selected from the group consisting of polyethylene, polypropylene, and
ethylene-vinyl acetate copolymer (EVA) may be used. As the resin having a curing
temperature ranging from room temperature up to 120 °C, reaction-curing resin
(e.g., epoxy resin, urethane resin, unsaturated polyester resin and the like),
thermosetting resin (e.g., phenol resin and the like), or the like may be used. As
the resin dissolvable in a solvent having an evaporating temperature that does not
exceed 120 °C, any one of the foregoing thermoplastic resins may be used. The

solvent-soluble resin is dissolved in a solvent, and added to an active material
substance, and the solvent is removed by evaporation, extraction, or other
technique. Additionally, as the resin dissolvable in a water-soluble and extractable
solvent, any one selected from the group consisting of polyether sulfone resin
(PES), polystyrene, polysulfone, polyacrylonitrile, polyvinylidene fluoride, polyamide,
polyimide and the like may be used. As the resin dissolvable in an alcohol-soluble
and extractable solvent, acetylcellulose, oxide phenylene ether (PPO), or the like
may be used.
By virtue of the above-described construction, the present invention
provides the following advantages.
1) The inventions for solving the first problem provide the following excellent
effects.
(1) When producing an electrode of a three-dimensional battery, it
becomes possible to reduce the number of component parts required at the time of
battery assembly, the time required for assembly, and the cost of assembly because
of formation by combination of an active material with at least one of a separator, a
dividing wall, and a current collector.
(2) By providing a dividing wall and a current collector with projected
portions in needle, plate, wave, particle, or the like form, the current collecting area
is increased. This makes charging and discharging at high rate (high current
charging and discharging) possible, thereby achieving improvements in battery
performance.
(3) By the use of an ion permeable current collector having therein voids,
the current collecting area is increased. This makes charging and discharging at
high rate (high current charging and discharging) possible, thereby achieving
improvements in battery performance,
(4) Because of the arrangement that a dividing wall and a current
collector are provided with a cooling structure, it becomes possible to suppress the
increase in temperature caused by a cell reaction, thereby achieving improvements
in battery performance.
2) The inventions for solving the second problem provide the following excellent
effects.

(1) Because of the arrangement that cathode active materials and anode
active materials are disposed into being bellows-shaped and facing each other
across a separator, the distance between these active materials is reduced, and the
distance for which electrons move is reduced, thereby achieving high output
powers. In addition, the length for which ions diffuse is reduced, thereby achieving
excellent diffusion of ions. Besides, when gas is generated from the active material
because of overcharge or the like, the gas flows to the opposite electrode and is
likely to be consumed easily, and sealing can be established easily.
(2) Because of the use of cathode and anode active materials each of
which is coated with an ion permeable current collector made of porous nickel or
the like, the distance between the active materials and the current collector is
reduced, and not only the distance for which electrons move is reduced, but also
the current collecting area is increased, thereby providing a high performance
battery whose electrical resistance is small.
(3) By the arrangement that a battery ceil is loaded with a plurality of
bellows-shaped units, the increase in size (magnification of scale) can be achieved
easily and, in addition, since there are no welds causing electrical resistance to
increase, the drop in performance due to the increase in size will not take place.
Additionally, the production cost and the production time can be reduced.
(4) Since the separator and the ion permeable current collector exist
relatively plentifully in the inside of the battery cell, the filling amount of each of
cathode and anode active materials per unit volume is small, thereby making it
possible to hold a plenty of electrolytic solution within the cell. Accordingly, the dry
out phenomenon, in which a solid-liquid reaction (a cell reaction) will no longer
occur due to electrolytic solution depletion, is unlikely to occur.

(5) If the thickness of active material is reduced because high power
battery performance is required, this relatively increases the ratio of separator and
ion permeable current collector. As a result, despite the drop in volume energy
density it becomes possible to obtain a high power battery.
(6) On the other hand, if the thickness of active material is increased
because high power battery performance is not required, this relatively reduces the
ratio of separator and ion permeable current collector. As a result, it becomes

possible to obtain a battery having a high volume energy density.
(7) Finally, any changes to the battery specification can be made just by
increasing or decreasing the thickness of active material, and desired battery
specifications can be obtained easily.
ACCOMPANYING
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
Figure 1 is a schematic view showing in cross section an arrangement of
an example of a battery having a particulate cathode active material and a
particulate anode active material;
Figure 2 is a view diagrammatically showing an example of a vessel
structure of a three-dimensional battery of the layered type;
Figure 3 is a top plan view showing an example of a current collector (a
dividing wall) provided with projected portions;
Figure 4 is a side view showing an example of a current collector (a
dividing wall) provided with projected portions;
Figure 5 is a perspective view showing an example of a current collector
(a dividing wall) having a cooling structure;
Figure 6 is a view diagrammatically showing an example (a basic unit) of a
high power type three-dimensional battery in accordance with a first embodiment of
the present invention;
Figure 7 is a view diagrammatically showing another example (a basic
unit) of the high power type three-dimensional battery in accordance with the first
embodiment of the present invention;
Figure 8 is a view diagrammatically showing an example (four basic units
loaded in parallel) of a high power type three-dimensional battery in accordance
with a second embodiment of the present invention;
Figure 9 is a view diagrammatically showing an example (laminated in
series four layers each comprising four basic units loaded in parallel) of a high
power type three-dimensional battery in accordance with a third embodiment of the
present invention;
Figure 10 is a view diagrammatically showing an example (a basic unit
with an active material of the thick type) of a high power type three-dimensional

battery in accordance with a fourth embodiment of the present invention;
Figure 11 is a view diagrammatically showing an example (a basic unit) of
a high power type three-dimensional battery in accordance with a fifth embodiment
of the present invention;
Figure 12 is a view diagrammatically showing another example (two basic
units loaded in parallel) of the high power type three-dimensional battery in
accordance with the fifth embodiment of the present invention;
Figure 13 is a partially enlarged view diagrammatically showing an
example of a high power type three-dimensional battery in accordance with a sixth
embodiment of the present invention;
Figure 14 is a partially enlarged view diagrammatically showing another
example of the high power type three-dimensional battery in accordance with the
sixth embodiment of the present invention;
Figure 15 is a partially enlarged view diagrammatically showing still
another example of the high power type three-dimensional battery in accordance
with the sixth embodiment of the present invention;
Figure 16 is a partially enlarged view diagrammatically showing a further
example of the high power type three-dimensional battery in accordance with the
sixth embodiment of the present invention; and
Figure 17 is a partially enlarged view diagrammatically showing a still
further example of the high power type three-dimensional battery in accordance with
the sixth embodiment of the present invention.
BEST MODE FOR CARRYING OUT THE INVENTION
Hereinafter, embodiments of the present invention will be described. It is
to be understood that the present invention is not limited to the following
embodiments at all. Adequate modifications of the present invention are possible to
make.
In the first place, the details of the cell reaction of a three-dimensional
battery will be explained with reference to Figure 1.
Figure 1 shows an example of a battery having a cathode active material in
the form of particles and an anode active material in the form of particles. As

shown in Figure 1, an anode vessel 2 and a cathode vessel 3 are so defined as to
face each other across an ion permeable filter (separator) 1. An anode active
material 4 in particle form is filled into the anode vessel 2, together with an
electrolyte solution. On the other hand, a cathode active material 5 in particle
form is filled into the cathode vessel 3, together with an electrolyte solution. These
active materials are present as fixed layers in the respective electrolyte solutions.
In Figure 1, each active material particle is shown such that it has the same size as
the other. In fact, these active material particles naturally differ in size from one
another.
The separator 1 is a filter which has electrical insulation properties and
which permits passage of ions therethrough, and is a membrane which does not
permit passage of powdered and particulate material. As the material of the
separator 1, for example, unglazed pottery, ion exchange resin membrane or high
polymer fabric may be used.
Furthermore, an anode current collector 6 which is an electrical conductor
is disposed in the inside of the anode vessel 2, while a cathode current collector 7
which is an electrical conductor is disposed in the inside of the cathode vessel 3.
The current collectors 6 and 7 are connected to a load means 8 (in the case of
discharging) or to a power generating means 8 (in the case of charging).
Reference numeral 9 denotes an electrolyte solution interface.
Next, with respect to the battery of the present embodiment, charging and
discharging mechanisms will be described below.
CHARGING
Electrons are supplied from the anode current collector 6 by application of
voltage to the battery. An electron released from the anode current collector 6
moves directly or through a powdered and particulate active material to the
powdered and particulate active material of the anode and reacts. An ion
generated by the reaction passes through the separator 1 and moves into the
cathode vessel 3. In the cathode vessel 3, the ion reacts with the powdered and
particulate active material of the cathode and discharges an electron. The electron
moves directly or through the powdered and particulate material to the cathode
current collector 7, and is delivered to the power generating means 8.

DISCHARGING
Electrons are supplied from the anode current collector 6 by application of
load to the battery. An active material positive-ionized in the inside of the anode
vessel 2 discharges electrons. An electron moves directly or through a powdered
and particulate material to the anode current collector 6. An ion generated by the
reaction passes through the separator 1 and moves into the cathode vessel 3. In
the cathoe vessel 3, the ion reacts with the powdered and particulate active material
of the cathode and with an electron. An electron moves directly or through the
powdered and particulate material to the cathode current collector 7, and is supplied
to the load means 8.
1) EMBODIMENTS FOR SOLVING THE FIRST PROBLEM
Referring next to Figure 2, is shown diagrammatically an example of a
vessel structure of a three-dimensional battery of the layered type. Figure 2 shows
a three-layered type three-dimensional battery. Cathode and anode vessels are
formed through a separator 10 which undergoes no degeneration such as corrosion
in an alkali electrolyte solution and which is capable of providing electrical insulation
and of permitting passage of ions therethrough. A cathode active material 12 is
loaded into the cathode vessel cell, together with an electrolyte (KOH, NaOH, LiOH
and the like) solution, while an anode active material 14 is loaded into the anode
vessel, together with an electrolyte (KOH, NaOH, LiOH and thelike) solution. Each
unit battery consisting of a cathode vessel and an anode vessel, is layered one
upon the other in series through a respective dividing wall 16 made of a material
which undergoes no degeneration such as corrosion in an alkali electrolyte solution,
which does not permit passage of ions, and which has electrical conductive
properties, and a cathode current collector 18 in contact with the cathode active
material 12 is disposed in a vessel at one end while an anode current collector 20
in contact with the anode active material 14 is disposed in a vessel at the other end.
The cathode current collector 18 and the anode current collector 20 are each
made of a material which undergoes no degeneration such as corrosion in an alkali
electrolyte solution, which does not permit passage of ions, and which has electrical
conductive properties, and electricity is taken outside through these current
collectors.

As the material of the separator 10, a textile or nonwoven cloth made of
any one of polytetrafluoroethylene, polyethylene, polypropylene, nylon and the like
or membrane filter may be used. As the material of each of the dividing wall 16,
the cathode current collector 18, and the anode current collector 20, a nickel metal
plate, a nickel metal foil, carbon, nickel-plated iron, nickel-plated stainless steel,
nickel-plated carbon and the like may be used. Additionally, the dividing wall 16,
the cathode current collector 18, and the anode current collector 20 may be shaped
like a flat plate. More preferably, these components are provided with projected
portions in needle, plate, wave, particle, or the like form for the purpose of providing
an increased current collecting area. For example, as shown in Figures 3 and 4, it
is possible to provide a current collector (or a dividing wall) 24 with projected
portions 26. Additionally, by the arrangement that refrigerant is made to flow in the
inside of each of the dividing wall 16, the cathode current collector 18, and the
anode current collector 20, it becomes possible to provide them with a cooling
structure. For example, Figure 5 shows an example cooling structure in which a
bellows-shaped heat transfer tube 30, through which refrigerant flows, is disposed in
the inside of a plate-like current collector (or a dividing wall) 28. Reference numeral
32 indicates a refrigerant inlet port. Reference numeral 34 indicates a refrigerant
outlet port.
In addition to the above, preferably an ion permeable current collector,
which has voids therein, which permits passage of ions therethrough, and which is
electrically conductive, is added as a current collector for bypass, for providing an
increased current collecting area by increasing the area of contact with the active
material. As the material of such a current collector, a nickel metal mesh, a
mesh-like body made of nickel-plated iron or nickel-plated stainless steel (for
example, punching metal, expanded metal and the like), foamed nickel metal,
nickel-plated foamed resin, nickel-plated carbon fibers, nickel-plated organic fibers,
nickel-plated felt, nickel-plated inorganic fibers made of silica, alumina and the like,
or nickel-plated foil made of inorganic substancesuch as mica may be used.
Referring to Figure 2, is shown an arrangement by way of example in which an ion
permeable current collector 22 is interposed between the separator 10 and the
cathode active material 12 and the ion permeable current collector 22 is connected

to the cathode current collector 18 to form a single current collector. Such an ion
permeable current collector may be disposed on the separator side so that larger
areas are brought into contact with the active material thereby increasing the current
collecting area.
In the above-described three-dimensional battery, active material
substances of all kinds may be used as an active material which causes a cell
reaction, regardless of the type of battery and regardless of cathode or anode. For
example, for the case of nickel-hydrogen batteries, the cathode active material 12
comprises nickel hydroxide and the anode active material 14 comprises a
hydrogen-occluding alloy. Additionally, for the case of NiCd batteries, the cathode
active material 12 comprises nickel hydroxide and the anode active material 14
comprises cadmium.
The active material may be in the form of powders. Alternatively, the
active material may made of a particulate or plate-shaped material with an
electrically conductive filler and a resin. The active material is combined with at
least two of a separator, a dividing wall, and a current collector (including ion
permeable current collector). And such a mixture is subjected to being formed
integrally with one another in one piece, and the resultant formation is used as an
electrode material. The way of producing such an electrode material will be
described later.
The electrically conductive filler comprises carbon fibers, nickel-plated
carbon fibers, carbon particles, nickel-plated carbon particles, nickel-plated organic
fibers, nickel-plated inorganic fibers made of silica, alumina and the like,
nickel-plated foil made of inorganic substance such as mica, nickel in fiber form,
nickel particles, nickel foil and the like.
As the resin that is added when shaping an active material into particle or
plate form, thermoplastic resins such as polyethylene, polypropylene, ethylene-vinyl
acetate copolymer and the like may be used. In this case, it may be arranged such
that a thermoplastic resin is melted by application of heat and is mixed with an
active material to uniformly disperse the active material. Alternatively, it may be
arranged such that a resin dissolved by a solvent is added. For example,
polyethylene, polypropylene, and ethylene-vinyl acetate copolymer are all soluble in

solvents such as heated benzene, heated toluene, heated xylene and the like.
A resin dissolved in such a solvent is mixed with an active material, and
with an electrically conductive filler if necessary. Thereafter, the solvent is removed
by evaporation, thereby making it possible to produce an active material forming
product cured by the resin.
Additionally, as a reaction-curing resin, epoxy resin, urethane resin,
unsaturated polyester resin or the like may be used, and a thermosetting resin, e.g.,
phenol resin, may be used as a binder.
Furthermore, in the case where a resin dissolved in a water-soluble solvent
is added when shaping an active material into particle, plate, or the like form, an
active material forming product cured by the resin is prepared by extraction and
removal of the solvent by the use of water. For example, polyether sulfone (PES)
resin is soluble in dimethyl sulfoxide (DMSO). Additionally, polystyrene is soluble in
acetone. Polysulfone is soluble in dimethylformamide (DMF) and DMSO.
Polyacrylonitrile is soluble in DMF, DMSO, and ethylene carbonate. Polyvinylidene
fluoride is soluble in DMF, DMSO, and N-methyl-2-pyrrolidone (NMP). Polyamide
is soluble in DMF and NMP. Polyimide is soluble in DMF and NMP.
Furthermore, in the case where a resin dissolved in an alcohol-soluble
solvent is added when shaping an active material into particle, plate, or the like
form, an active material forming product cured by the resin is prepared by extraction
and removal of the solvent by the use of alcohol. For example, acetyl cellulose is
soluble in methylene chloride. Oxide phenylene ether (PPO) is soluble in
methylene chloride.
Additionally, the surface of an active material shaped into particle, plate, or
the like form may be coated with electrical conductive materials such as carbon
fibers, nickel-plated carbon fibers, nickel-plated organic fibers, nickel-plated
inorganic fibers made of silica, alumina and the like, nickel-plated foil made of
inorganic substance such as mica, carbon powder, nickel-plated carbon powder,
nickel in fiber form, nickel powders, nickel foil and the like. Such coating is carried
out as follows. Before the active material formed substance is cured, a coating
material such as any one of the above-described metal powders, metal fibers,
metal-plated fibers and the like is added. By rolling, stirring or the like, the coating

material is adhered to the outer surface of the forming product in a soft state. For
the case of a forming product cured by resin, for the case of a forming product
employing a thermosoftening resin, or for the case of a forming product employing a
solvent-soluble resin, each of the forming products is placed in the uncured state by
increasing the temperature of the forming product for softening by application of
heat or by swelling and softening by addition of a solvent, and an impregnated
metal is added to the forming product for impregnation. Additionally, a surface of
the active material in particle, plate, or the like form may be plated with nickel.
A method of producing an electrode material of the three-dimensional
battery in accordance with the present invention will be described. When producing
an electrode of a three-dimensional battery, an active material of the
above-described composition is combined with any one or at least two of a
separator, a dividing wall, and a current collector (including an ion permeable
current collector) so that they are formed integrally with one another in one piece.
Such formation is carried out as follows. A mixture of a powdered active
material with an electrically conducive filler and a resin is stirred. The mixture is
integrally combined with a separator, a dividing wall and/or a current collector.
Then, pressurized forming is carried out while applying heat. In this case, the
formation can be achieved by the use of a resin mixed with an electrically
conductive filler without application of pressure. As the resin, thermoplastic resins
such as polyethylene, polypropylene, ethylene-vinyl acetate copolymer and the like
may be used.
Additionally, a thermoplastic resin dissolved in a solvent such as heated
toluene, heated xylene and the like is mixed with a powdered active material and an
electrically conductive filler to uniformly disperse the active material and the filler.
Then, the mixture is stirred and granulated to form granulated particles. These
granulated particles are integrally combined with a separator, a dividing wall and/or
a current collector. Then, pressurizede forming is carried out while applying heat.
At this time, it is possible to cure the resin by evaporating the solvent contained in
the forming product. Also in this case, the formation can be achieved by the use of
a resin mixed with an electrically conductive filler without application of pressure.
Furthermore, in the case where an active material shaped into particle,

plate, or the like form is integrally formed in one piece with a separator, a dividing
wall and/or a current collector, such formation can be carried out by re-dissolving
the resin contained in the forming product without addition of a new resin.
Additionally, it is possible to provide integral formation in one piece by the
use of a reaction-curing resin (such as epoxy resin, urethane resin, unsaturated
polyester resin and the like) or a thermosetting resin such as phenol resin.
The aforesaid integral formation in one piece may be achieved by using, as
a resin dissolved in a water-soluble solvent, a PES resin dissolved in DMSO,
polystyrene dissolved in acetone, polysulfone dissolved in DMF or DMSO,
polyacrylonitrile dissolved in DMF, DMSO, or ethylene carbonate, polyvinylidene
fluoride dissolved in DMF, DMSO, or NMP, polyamide dissolved in DMF or NMP, or
polyimide dissolved in DMF or NMP, in this case the solvent is extracted and
removed from the forming product by the use of water. Additionally, the integral
formation in one piece may be achieved by using, as a resin dissolved in an
alcohol-soluble solvent, acetyl cellulose dissolved in methylene chloride, oxide
phenylene ether (PPO) dissolved in methylene chloride or the like, in this case the
solvent is extracted and removed from the forming product by the use of alcohol.
In the structure of an electrode produced in accordance with the method of
the present invention, an active material is combined with at least two of a
separator, a dividing wall, and a current collector, thereby reducing the number of
component parts required at the time of three-dimensional battery assembly, the
time required for assembly, and the costs of assembly.
Hereinafter, embodiment examples of the present invention will be
described.
EMBODIMENT 1
150 g of particulate graphite (acetylene black) was put into a Henschel
mixer having an internal volume of 10 litters. The graphite particles were stirred at
1000 rpm for about three minutes to obtain thorough dispersion thereof. Then,
1000 g of nickel hydroxide powders and 100 g of carbon fibers (trade name: DONA
CARBO S-247) were added into the content of the mixer. Then, the mixer was
operated for performing mixing operation at 1000 rpm for about three minutes. This
was followed by addition of 150 g of ethylene-vinyl acetate copolymer into the

mixer. Then, mixing and stirring was carried out at a temperature of not less than
the softening temperature nor more than 130 °C for ten minutes. The resultant
substance, i.e., a nickel hydroxide mixture, was poured onto a separator (a nylon
nonwoven cloth) previously spread over the bottom of a mold frame having a cross
section of 100 mm x 100 mm. While applying heat from above, a pressure of 0.1
MPa was applied for achieving pressurized forming, and in such a state the
temperature was reduced to cause the resin to cure. A forming product thus
formed was removed from the mold frame. In this way, an electrode material
comprising an integral formation in one piece of the active material with the
separator was obtained.
EMBODIMENT 2
Nickel hydroxide powders, an electrically conductive filler, and a resin were
mixed together with stirring in the same way as the first embodiment, to prepare a
nickel hydroxide mixture. A separator (a nylon nonwoven cloth) was previously
spread over the bottom of a mold frame having a cross section of 100 mm x 100
mm. Then, the nickel hydroxide mixture was poured, from above, onto the
separator. The mixture was cooled as it was in the molding frame without
application of pressure, thereby causing the resin to cure. A forming product thus
formed was removed from the mold frame. In this way, an electrode material
comprising an integral formation in one piece of the active material with the
separator was obtained.
EMBODIMENT 3
Nickel hydroxide powders, an electrically conductive filler, and a resin were
mixed together with stirring in the same way as the first embodiment, to prepare a
nickel hydroxide mixture. A current collector (a nickel plate) was previously spread
over the bottom of a mold frame having a cross section of 100 mm x 100 mm.
Then, the nickel hydroxide mixture was poured, from above, onto the current
collector . While applying heat from above, a pressure of 0.1 MPa was applied for
achieving pressurized forming, and in such a state the temperature was reduced to
cause the resin to cure. A forming product thus formed was removed from the
mold frame. In this way, an electrode material comprising an integral formation in
one piece of the active material with the current collector was obtained.

EMBODIMENT 4
Nickel hydroxide powders, an electrically conductive filler, and a resin were
mixed together with stirring in the same way as the first embodiment, to prepare a
nickel hydroxide mixture. A current collector (a nickel plate) was previously spread
over the bottom of a mold frame having a cross section of 100 mm x 100 nm. The
nickel hydroxide mixture was poured, from above, onto the current collector. The
mixture was cooled as it was in the molding frame without application of pressure,
thereby causing the resin to cure. A forming product thus formed was removed
from the mold frame. In this way, an electrode material comprising an integral
formation in one piece of the active material with the current collector was obtained.
EMBODIMENT 5
Nickel hydroxide powders, an electrically conductive filler, and a resin were
mixed together with stirring in the same way as the first embodiment, to prepare a
nickel hydroxide mixture. A separator (a nylon nonwoven cloth) was previously
spread over the bottom of a mold frame having a cross section of 100 mm x 100
mm. Then, the nickel hydroxide mixture was poured, from above, onto the
separator. Additionally, a current collector (a nickel plate) was placed on the filled
nickel hydroxide mixture. While applying heat from above, a pressure of 0.1 MPa
was applied for achieving pressurized forming, and in such a state the temperature
was reduced to cause the resin to cure. A forming product thus formed was
removed from the mold frame. In this way, an electrode material comprising an
integral formation in one piece of the active material with the separator and the
current collector was obtained.
EMBODIMENT 6
Nickel hydroxide powders, an electrically conductive filler, and a resin were
mixed together with stirring in the same way as the first embodiment, to prepare a
nickel hydroxide mixture. A separator (a nylon nonwoven cloth) was previously
spread over the bottom of a mold frame having a cross section of 100 mm x 100
mm. And, the nickel hydroxide mixture was poured, from above, onto the
separator. Additionally, a current collector (a nickel plate) was placed on the filled
nickel hydroxide mixture. The mixture was cooled as it was in the molding frame
without application of pressure, thereby causing the resin to cure. A forming

product thus formed was removed from the mold frame. In this way, an electrode
material comprising an integral formation in one piece of the active material with the
separator and current collector was obtained.
EMBODIMENT 7
Nickel hydroxide powders, an electrically conductive filler, and a resin were
mixed together with stirring in the same way as the first embodiment, to prepare a
nickel hydroxide mixture. A separator (a nylon nonwoven cloth) was previously
spread over the bottom of a mold frame having a cross section of 100 mm x 100
mm. And, an ion permeable current collector (a foamed nickel sheet) was placed
on the separator. Then, the nickel hydroxide mixture was poured from above.
This was followed by placement of a current collector (a nickel plate) on the filled
nickel hydroxide mixture. At this time, it was arranged such that the ion permeable
current collector came into contact with the current collector. While applying heat
from above, a pressure of 0.1 MPa was applied for achieving pressurized forming,
and in such a state the temperature was reduced to cause the resin to curen. A
forming product thus formed was removed from the mold frame. In this way, an
electrode material comprising an integral formation in one piece of the active
material with the separator, ion permeable current collector and current collector
was obtained.
EMBODIMENT 8
Nickel hydroxide powders, an electrically conductive filler, and a resin were
mixed together with stirring in the same way as the first embodiment, to prepare a
nickel hydroxide mixture. A separator (a nylon nonwoven cloth) was previously
spread over the bottom of a mold frame having a cross section of 100 mm x 100
mm. And, an ion permeable current collector (a foamed nickel sheet) was placed
on the separator. Then, the nickel hydroxide mixture was poured from above.
This was followed by placement of a current collector (a nickel plate) on the filled
nickel hydroxide mixture. At this time, it was arranged such that the ion permeable
current collector came into contact with the current collector. The mixture was
cooled as it was in the molding frame without application of pressure, thereby
causing the resin to cure. A forming product thus formed was removed from the
mold frame. In this way, an electrode material comprising an integral formation in

one piece of the active material with the separator, ion permeable current collector
and current collector was obtained.
EMBODIMENT 9
150 g of particulate graphite (acetylene black) was put into a Henschel
mixer having an internal volume of 10 litters. The graphite particles were stirred at
1000 rpm for about three minutes to obtain thorough dispersion thereof. Then,
1000 g of nickel hydroxide powders and 100 g of carbon fibers (trade name:
DONACARBO S-247) were added to the content of the mixer. Then, the mixer was
operated for performing mixing operation at 1000 rpm for about three minutes.
Separately, 150 g of ethylene-vinyl acetate copolymer was added to 1000 g of
xylene heated to a temperature of 60 °C for dissolution therein. The resin
dissolved in the heated xylene was added to a mixture of the nickel hydroxide
powders and electrically conductive filler, heated to a temperature of 60 °C. While
maintaining temperature at 60 °C by application of heat, the content of the
Henschel mixer was stirred. Then, the Henschel mixer was cooled while still
continuing stirring, and the mixed and kneaded substance was cooled and ground
into powders. The powders were put into a high speed mixer and were entirely
stirred by an agitator while at the same time controlling the size of granulated
particles by means of a chopper. The internal volume of the high speed mixer used
was 2 litters The speed of rotation of the agitator used was 600 rpm. The speed
of rotation of the chopper used was 1500 rpm. Under these conditions, the
temperature of the powders was increased from room temperature up to 50 °C with
stirring. After generation of granulated particles, stirring was stopped while still
continuing cooling. The particles contained therein xylene. Accordingly, the
particles were placed in a reduced pressure dryer and heated to 50 °C, for removal
of the xylene therefrom. After being cooled, the particles were sieved with a sieve
having a mesh size of 2.88 mm and with a sieve having a mesh size of 1 mm. As
a result, granulated particles ranging in size between 1 mm and 2.88 mm were
obtained.
A current collector (a nickel plate) was previously spread over the bottom
of a mold frame having a cross section of 100 mm x 100 mm. Then, the
granulated particles were poured, from above, onto the current collector. While

applying heat from above, a pressure of 0.1 MPa was applied for achieving
pressurized forming, and in such a state the temperature was reduced to cause the
resin to cure. A framing product thus formed was removed from the mold frame.
In this way, an electrode material comprising an integral formation in one piece of
the active material with the current collector was obtained.
EMBODIMENT 10
Nickel hydroxide powders, an electrically conductive filler, and a resin were
mixed together with stirring for granulation in the same way as the ninth
embodiment. A current collector (a nickel plate) was previously spread over the
bottom of a mold frame having a cross section of 100 mm x 100 mm. Then, the
granulated particles was poured, from above, onto the current collector. The
granulated particles were cooled in the molding frame without application of
pressure, thereby causing the resin to harden. A forming product thus formed was
removed from the mold frame. In this way, an electrode material comprising an
integral formation in one piece of the active material with the current collector was
obtained.
EMBODIMENT 11
150 g of particulate graphite (acetylene black) was put into a Henschel
mixer having an internal volume of 10 litters. The graphite particles were stirred at
1000 rpm for about three minutes to obtain thorough dispersion thereof. Then,
2500 g of hydrogen-occluding alloy powders and 100 g of carbon fibers (trade
name: DONACARBO S-247) were added to the content of the mixer. Then, the
mixer was operated for performing mixing operation at 1000 rpm for about three
minutes. Separately, 150 g of ethylene-vinyl acetate copolymer was added to 1000
g of xylene heated to a temperature of 60 °C for dissolution therein. The resin
dissolved in the heated xylene was added to a mixture of the hydrogen-occluding
alloy powders and electrically conductive filler, heated to a temperature of 60 °C.
While maintaining temperature at 60 °C by application of heat, the content of the
Henschel mixer was stirred. Then, the Henschel mixer was cooled while still
continuing stirring, and the mixed and kneaded substance was cooled and ground
into powders. The powders were put in a high speed mixer and were entirely
stirred by an agitator while at the same time controlling the size of granulated

particles by means of a chopper. The internal volume of the high speed mixer used
was 2 litters. The speed of rotation of the agitator used was 600 rpm. The speed
of rotation of the chopper used was 1500 rpm. Under these conditions, the
temperature of the powders was increased from room temperature to 50 °C with
stirring. After generation of granulated particles, stirring was stopped while still
continuing cooling. The particles contained therein xylene. Accordingly, the
particles were placed in a reduced pressure dryer and heated to 50 °C for removal
of the xylene therefrom. After being cooled, the particles were sieved with a sieve
having a mesh size of 2.88 mm and with a sieve having a mesh size of 1 mm. As
a result, granulated particles ranging in size between 1 mm and 2.88 mm were
obtained.
A current collector (a nickel plate) was previously spread over the bottom
of a mold frame having a cross section of 100 mm x 100 mm. Then, the
granulated particles were poured, from above, onto the current collector. While
applying heat from above, a pressure of 0.1 MPa was applied for achieving
pressurized forming, and in such a state the temperature was reduced to cause the
resin to cure. A forming product thus formed was removed from the mold frame.
In this way, an electrode material comprising an integral formation in one piece of
the active material with the current collector was obtained.
EMBODIMENT 12
150 g of particulate graphite (acetylene black) was put into a Henschel
mixer having an internal volume of 10 litters. The graphite particles were stirred at
1000 rpm for about three minutes to obtain thorough dispersion thereof. Then,
2500 g of sand (Toyoura standard sand) and 100 g of carbon fibers (trade name:
DONACARBO S-247) were added to the content of the mixer. Then, the mixer was
operated for performing mixing operation at 1000 rpm for about three minutes.
Separately, 150 g of ethylene-vinyl acetate copolymer was added to 1000 g of
xylene heated to a temperature of 60 °C for dissolution therein. The resin
dissolved in the heated xylene was added to a mixture of the sand and electrically
conductive filler, heated to a temperature of 60 °C. While maintaining temperature
at 60 degrees Centigrade by application of heat, the content of the Henschel mixer
was stirred. Then, the Henschel mixer was cooled while still continuing stirring, and

the mixed/kneaded substance was cooled and ground to powders. The powders
were put into a high speed mixer and were entirely stirred by an agitator while at
the same time controlling the size of granulated particles by means of a chopper.
The internal volume of the high speed mixer used was 2 litters. The speed of
rotation of the agitator used was 600 rpm. The speed of rotation of the chopper
used was 1500 rpm. Under these conditions, the temperature of the powders was
increased from room temperature to 50 t with stirring. After generation of
granulated particles, stirring was stopped while still continuing cooling. The
particles contained therein xylene. Accordingly, the particles were placed in a
reduced pressure dryer and heated to 50 °C for removal of the xylene therefrom.
After being cooled, the particles were sieved with a sieve having a mesh size of
2.88 mm and with a sieve having a mesh size of 1 mm. As a result, granulated
particles ranging in size between 1 mm and 2.88 mm were obtained.
A current collector (a nickel plate) was previously spread over the bottom
of a mold frame having a cross section of 100 mm x 100 mm. Then, the
granulated particles were poured, from above, onto the current collector. While
applying heat from above, a pressure of 0.1 MPa was applied for achieving
pressurized forming, and in such a state the temperature was reduced to cause the
resin to cure. A forming product thus formed was removed 1rom the mold frame.
In this way, an electrode material comprising an integral formation in one piece of
the active material with the current collector was obtained.
EMBODIMENT 13
150 g of particulate graphite (acetylene black) was put into a Henschel
mixer having an internal volume of 10 litters. The graphite particles were stirred at
1000 rpm for about three minutes to obtain thorough dispersion thereof. Then,
1000 g of particulate coal (powdered coal of Daido coal) and 100 g of carbon fibers
(trade name: DONACARBO S-247) were added to the content of the mixer. Then,
the mixer was operated for performing mixing operation at 1000 rpm for about three
minutes. Separately, 150 g of ethylene-vinyl acetate copolymer was added to 1000
g of xylene heated to a temperature of 60 °C for dissolution therein. The resin
dissolved in the heated xylene was added to a mixture of the coal and electrically
conductive filter, heated to a temperature of 60 °C. While maintaining temperature

at 60 degrees Centigrade by application of heat, the content of the Henschel mixer
was stirred. Then, the Henschel mixer was cooled while still continuing stirring, and
the mixed and kneaded substance was cooled and ground to powders. The
powders were put in a high speed mixer and were entirely stirred by an agitator
while at the same time controlling the size of granulated particles by means of a
chopper. The internal volume of the high speed mixer used was 2 litters. The
speed of rotation of the agitator used was 600 rpm. The speed of rotation of the
chopper used was 1500 rpm. Under these conditions, the temperature of the
powders was increased from room temperature to 50 °C with stirring. After
generation of granulated particles, stirring was stopped while still continuing cooling.
The particles contained therein xylene. Accordingly, the particles were placed in a
reduced pressure dryer and heated to a temperature of 50 °C for removal of the
xylene therefrom. After being cooled, the particles were sieved with a sieve having
a mesh size of 2.88 mm and with a sieve having a mesh size of 1 mm. As a result,
granulated particles ranging in size between 1 mm and 2.88 mm were obtained.
A current collector (a nickel plate) was previously spread over the bottom
of a mold frame having a cross section of 100 mm x 100 mm. Then, the
granulated particles were poured, from above, onto the current collector. While
applying heat from above, a pressure of 0.1 MPa was applied for achieving
pressurized forming, and in such a state the temperature was reduced to cause the
resin to cure. A forming product thus formed was removed from the mold frame.
In this way, an electrode material comprising an integral formation in one piece of
the active material with the current collector was obtained.
EMBODIMENT 14
150 g of particulate graphite (acetylene black) was put into a Henschel
mixer having an internal volume of 10 litters. The graphite particles were stirred at
1000 rpm for about three minutes to obtain thorough dispersion thereof. Then, 500
g of charcoal (prepared by calcining wood at 600 °C for two hours) and 100 g of
carbon fibers (trade name: DONACARBO S-247) were added to the content of the
mixer. Then, the mixer was operated for performing mixing operation at 1000 rpm
for about three minutes. Separately, 150 g of ethylene-vinyl acetate copolymer was
added to 1000 g of xylene heated to a temperature of 60 °C for dissolution therein.

The resin dissolved in the heated xylene was added to a mixture of the charcoal
and electrically conductive filler, heated to a temperature of 60 °C. While
maintaining temperature at 60 °C by application of heat, the content of the
Henschel mixer was stirred. Then, the Henschel mixer was cooled while still
continuing stirring, and the mixed and kneaded substance was cooled and ground
to powders. The powders were put in a high speed mixer and were entirely stirred
by an agitator while at the same time controlling the size of granulated particles by
means of a chopper. The internal volume of the high speed mixer used was 2
litters. The speed of rotation of the agitator used was 600 rpm. The speed of
rotation of the chopper used was 1500 rpm. Under these conditions, the
temperature of the powders was increased from room temperature to 50 °C with
stirring. After generation of granulated particles, stirring was stopped while still
continuing cooling. The particles contained therein xylene. Accordingly, the
particles were placed in a reduced pressure dryer and heated to 50 °C for removal
of the xylene therefrom. After being cooled, the particles were sieved with a sieve
having a mesh size of 2.88 mm and with a sieve having a mesh size of 1 mm. As
a result, granulated particles ranging in size between 1 mm and 2.88 mm were
obtained.
A current collector (a nickel plate) was previously spread over the bottom
of a mold frame having a cross section of 100 mm x 100 mm. Then, the
granulated particles were poured, from above, onto the current collector. While
applying heat from above, a pressure of 0.1 MPa was applied for achieving
pressurized forming, and in such a state the temperature was reduced to cause the
resin to cure. A forming product thus formed was removed from the mold frame.
In this way, an electrode material comprising an integral formation in one piece of
the active material with the current collector was obtained.
EMBODIMENT 15
150 g of particulate graphite (acetylene black) was put into a Henschel
mixer having an internal volume of 10 litters. The graphite particles were stirred at
1000 rpm for about three minutes to obtain thorough dispersion thereof. Then,
500 g of silica (obtained by calcining chaff at 600 °C for two hours) and 100 g of
carbon fibers (trade name: DONACARBO S-247) were added to the content of the

mixer. Then, the mixer was operated for performing mixing operation at 1000 rpm
for about three minutes. Separately, 150 g of ethylene-vinyl acetate copolymer was
added to 1000 g of xylene heated to a temperature of 60 °C for dissolution therein.
The resin dissolved in the heated xylene was added to a mixture of the silica and
electrically conductive filler, heated to a temperature of 60 °C. While maintaining
temperature at 60 °C by application of heat, the content of the Henschel mixer was
stirred. Then, the Henschel mixer was cooled while still continuing stirring, and the
mixed and kneaded substance was cooled and ground to powders. The powders
were put in a high speed mixer and were entirely stirred by an agitator while at the
same time controlling the size of granulated particles by means of a chopper. The
internal volume of the high speed mixer used was 2 litters. The speed of rotation of
the agitator used was 600 rpm. The speed of rotation of the chopper used was
1500 rpm. Under these conditions, the temperature of the powders was increased
from room temperature up to 50 °C with stirring. After generation of granulated
particles, stirring was stopped while still continuing cooling. The particles contained
therein xylene. Accordingly, the particles were placed in a reduced pressure dryer
and were heated up to 50 °C. for removal of the xylene therefrom. After being
cooled, the particles were sieved with a sieve having a mesh size of 2.88 mm and
with a sieve having a mesh size of 1 mm. As a result, granulated particles ranging
in size between 1 mm and 2.88 mm were obtained.
A current collector (a nickel plate) was previously spread over the bottom
of a mold frame having a cross section of 100 mm x 100 mm. Then, the
granulated particles were poured, from above, onto the current collector. While
applying heat from above, a pressure of 0.1 MPa was applied for achieving
pressurized forming, and in such a state the temperature was reduced to cause the
resin to cure. A forming product thus formed was removed from the mold frame.
In this way, an electrode material comprising an integral formation in one piece of
the active material with the current collector was obtained.
EMBODIMENT 16
150 g of particulate graphite (acetylene black) was put into a Henschel
mixer having an internal volume of 10 litters. These graphite particles were stirred
at 1000 rpm for about three minutes to obtain thorough dispersion thereof. Then,

1000 g of slag (prepared by melting refuse incineration ash at 1500 °C and then by
cooling it) and 100 g of carbon fibers (trade name: DONACARBO S-247) were
added to the content of the mixer. Then, the mixer was operated for performing
mixing operation at 1000 rpm for about three minutes. Separately, 150 g of
ethylene-vinyl acetate copolymer was added to 1000 g of xylene heated to a
temperature of 60 °C for dissolution therein. The resin dissolved in the heated
xylene was added to a mixture of the slag and electrically conductive filler, heated
to a temperature of 60 °C. While maintaining temperature at 60 °C, by application
of heat, the content of the Henschel mixer was stirred. Then, the Henschel mixer
was cooled while still continuing stirring, and the mixed and kneaded substance was
cooled and ground to powders. The powders were put in a high speed mixer and
were entirely stirred by an agitator while at the same time controlling the size of
granulated particles by means of a chopper. The internal volume of the high speed
mixer used was 2 litters. The speed of rotation of the agitator used was 600 rpm.
The speed of rotation of the chopper used was 1500 rpm. Under these conditions,
the temperature of the powders was increased from room temperature to 50 °C with
stirring. After generation of granulated particles, stirring was stopped while still
continuing cooling. The particles contained therein xylene. Accordingly, the
particles were placed in a reduced pressure dryer and were heated to 50 °C for
removal of the xylene therefrom. After being cooled, the particles were sieved with
a sieve having a mesh size of 2.88 mm and with a sieve having a mesh size of 1
mm. As a result, granulated particles ranging in size between 1 mm and 2.88 mm
were obtained.
A current collector (a nickel plate) was previously spread over the bottom
of a mold frame having a cross section of 100 mm x 100 mm. Then, the
granulated particles were poured, from above, onto the current collector. While
applying heat from above, a pressure of 0.1 MPa was applied for achieving
pressurized forming, and in such a state the temperature was reduced to cause the
resin to cure. A forming product thus formed was removed from the mold frame.
In this way, an electrode material comprising an integral formation in one piece of
the active material with the current collector was obtained.
EMBODIMENT 17

150 g of particulate graphite (acetylene black) was put into a Henschel
mixer having an internal volume of 10 litters. The graphite particles were stirred at
1000 rpm for about three minutes to obtain thorough dispersion thereof. Then, 500
g of carbon (prepared by calcining carbon fibers at 1100 °C) was added to the
content of the mixer. Then, the mixer was operated for performing mixing operation
at 1000 rpm for about three minutes. Separately, 150 g of ethylene-vinyl acetate
copolymer was added to 1000 g of xylene heated to a temperature of 60 °C for
dissolution therein. The resin dissolved in the heated xylene was added to a
mixture of the carbon and electrically conductive filler, heated to a temperature of 60
°C. While maintaining temperature at 60 °C by application of heat, the content of
the Henschel mixer was stirred. Then, the Henschel mixer was cooled while still
continuing stirring, and the mixed and kneaded substance was cooled and ground
to powders. The powders were put in a high speed mixer and were entirely stirred
by an agitator while at the same time controlling the size of granulated particles by
means of a chopper. The internal volume of the high speed mixer used was 2
litters. The speed of rotation of the agitator used was 600 rpm. The speed of
rotation of the chopper used was 1500 rpm. Under these conditions, the
temperature of the powders was increased from room temperature up to 50 °C with
stirring. After generation of granulated particles, stirring was stopped while still
continuing cooling. The particles contained therein xylene. Accordingly, the
particles were placed in a reduced pressure dryer and were heated to 50 °C for
removal of the xylene therefrom. After being cooled, the particles were sieved with
a sieve having a mesh size of 2.88 mm and with a sieve having a mesh size of 1
mm. As a result, granulated particles ranging in size between 1 mm and 2.88 mm
were obtained.
A current collector (a nickel plate) was previously spread over the bottom
of a mold frame having a cross section of 100 mm x 100 mm. Then, the
granulated particles were poured, from above, onto the current collector. While
applying heat from above, a pressure of 0.1 MPa was applied for achieving
pressurized forming, and in such a state the temperature was reduced to cause the
resin to cure. A forming product thus formed was removed from the mold frame.
In this way, an electrode material comprising an integral formation in one piece of

the active material with the current collector was obtained.
EMBODIMENT 18
Nickel hydroxide powders, an electrically conductive filler, and a resin were
mixed together with stirring in the same way as the first embodiment, to prepare a
nickel hydroxide mixture. A current collector provided with projected portions as
shown in Figures 3 and 4 (a nickel current collector designed for a battery cell
internal size of 100 mm x 100 mm x 10 mm: a current collector provided with 8
mm-long projected portions at pitches of 10 mm) was prepared. The current
collector provided with such projected portions was previously spread over the
bottom of a mold frame having a cross section of 100 mm by 100 mm. Then, the
nickel hydroxide mixture was poured, from above, onto the current collector. While
applying heat from above, a pressure of 0.1 MPa was applied for achieving
pressurized forming, and in such a state the temperature was reduced to cause the
resin to cure. A forming product thus formed was removed from the mold frame.
In this way, an electrode material comprising an integral formation in one piece of
the active material with the current collector was obtained.
EMBODIMENT 19
Nickel hydroxide powders, an electrically conductive filler, and a resin were
mixed together with stirring in the same way as the first embodiment, to prepare a
nickel hydroxide mixture. A current collector having a cooling structure as shown in
Figure 5 (a nickel current collector designed for a battery cell internal size of 100
mm x 100 mm x 10 mm: a current collector in which is disposed a heat transfer pipe
through which a refrigerant such as water flows) was prepared. The current
collector provided with such a cooling structure was previously spread over the
bottom of a mold frame having a cross section of 100 mm x 100 mm. Then, the
nickel hydroxide mixture was poured, from above, onto the current collector. While
applying heat from above, a pressure of 0.1 MPa was applied for achieving
pressurized forming, and in such a state the temperature was reduced to cause the
resin to cure. A forming product thus formed was removed from the mold frame.
In this way, an electrode material comprising an integral formation in one piece of
the active material with the current collector was obtained.
2) EMBODIMENTS FOR SOLVING THE SECOND PROBLEM

Referring to Figure 6, is shown an example of a first embodiment of a high
power type three-dimensional battery in accordance with the present invention.
The present embodiment is a battery that is constructed of a single basic unit alone.
A resin and an electrically conductive filler are added to an active material
substance which causes a cell reaction, and the mixture is formed and cured to
prepare an active material forming product in particle, plate, block, rod, or the like
form. In this case, an active material substance in the form of powders may be
used as it is. Alternatively, a secondarily formed active material in the form of
particles may be used. Additionally, a powdered or particulate active material like
paste by the use of PVA or the like may be used. Active material substances of all
kinds may be used to form an active material capable of causing a cell reaction,
regardless of the type of battery and regardless of cathode or anode. For the case
of nickel-hydrogen secondary batteries, for example, 2000 g of nickel hydroxide
powders, 200 g of EVA resin, and 300 g of electrically conductive filler (carbon
black and carbon fibers) are mixed together and, thereafter, the mixture is subjected
to pressurized forming by application of a pressure of 0.1 MPa to form a plate-like
cathode active material 40 (100 mm x 30 mm x 3 mm (thickness)). Likewise, for
the case of nickel-hydrogen secondary batteries, for example, 6000 g of
hydrogen-occluding alloy powders, 200 g of EVA resin, and 300 g of electrically
conductive filler (carbon black and carbon fibers) are mixed together and, thereafter,
the mixture is subjected to pressurized forming by application of a pressure of 0.1
MPa to form a plate-like anode active material 42 (100 mm x 30 mm x 2 mm
(thickness)).
The cathode and anode active materials 40, 42 are each coated with an
ion permeable current collector 44. For example, for the case of each plate-like
active material, any surface(s) (from one to six surfaces) thereof may be coated with
the ion permeable current collector 44. Additionally, in the active material forming
step described above, the active material may be coated with an ion permeable
current collector for integral formation. Furthermore, when using an active material
in powder or paste form, it is advisable that the active material is filled in an ion
permeable current collector in the form of a sack. In the present embodiment, for
example, four of the surfaces of each of the plate-like cathode and anode active

materials 40, 42 are coated with the ion permeable current collector 44 (a foamed
nickel sheet). As the material of the ion permeable current collector that has voids
therein, permits passage of ions therethrough, and is electrically conductive, a nickel
metal mesh, a nickel-plated punching metal, a metal such as expanded metal, a
nickel-plated foamed resin such as urethane, nickel-plated porous material such as
polyethylene, polypropylene, nylon, cotton, carbon fibers and the like, nickel-plated
inorganic fibers made of silica, alumina and the like, nickel-plated organic fibers,
nickel-plated felt, or nickel-plated foil made of inorganic substance such as mica,
may be used in addition to the foamed nickel metal.
A bellows-shaped separator 46 consisting of a material which undergoes
no degeneration such as corrosion in an alkali electrolyte solution and which is
capable of both providing electrical insulation and permitting passage of ions
therethrough, is disposed. Cathode active materials 40 and anode active materials
42, when loaded in the battery cell, are placed alternately on the contact side with a
cathode current collector 48 and on the contact side with an anode current collector
50, respectively, facing each other across the separator 46. A basic unit thus
prepared is loaded, together with an electrolyte (KOH, NaOH, LiOH and the like)
solution, between the cathode current collector 48 and the anode current collector
50 in the battery cell to complete a battery. As the material of the separator 46, a
textile or nonwoven cloth made of any one of polytetrafluoroethylene, polyethylene,
polypropylene, nylon and the like, or membrane filter may be used. As the material
of each of the cathode current collector 48 and the anode current collector 50, a
nickel metal plate, a nickel metal foil, carbon, nickel-plated iron, nickel-plated
stainless steel, nickel-plated carbon and the like may be used.
The structure of the bellows-shaped unit, which is a basic unit, is not
limited to the one made up of a pair of cathode active materials and a pair of anode
active materials, as shown in Fig.6. The bellows-like unit may be produced by
adequately selecting a structure. For example, the bellows-shaped unit may be
formed using a minimum structure as shown in Figure 7 or a structure made up of
any number of pairs of cathode and anode active materials.
The details of the charging and discharging of the battery of the present
invention will be describe below.

CHARGING
A voltage is applied to the battery for the supply of electrons from a power
generating means (not shown) to the anode current collector 50. The electrons
move from the anode current collector 50 to the anode active material 42 and react.
Ions generated by the reaction pass through the separator 46, react with the
cathode active material 40, and discharge electrons. These electrons move to the
cathode current collector 48, and are delivered to the power generating means.
DISCHARGING
Electrons are supplied from a load to the cathode current collector 48.
The electrons move from the cathode current collector 48 to the cathode active
material 40 and react. Ions generated by the reaction pass through the separator
46, react with the anode active material 42, and discharge electrons. These
electrons move to the anode current collector 50, and are delivered to the load.
In the battery in which the cathode active material 40 and the anode active
material 42 are disposed facing each other across the bellows-shaped separator 46,
the distance between the cathode active material 40 and the anode active material
42 is short, and the distance for which electrons move becomes short, thereby
achieving high output powers. In addition, the length for which ions diffuse
becomes short, thereby achieving excellent diffusion of ions. Besides, when gas is
generated from the active material because of overcharge or the like, the gas flows
to its opposite electrode and is likely to be consumed easily, and sealing is
established easily.
In addition, if the cathode active material 40 and the anode active material
44, both of which are covered with the ion permeable current collector 44 made of
porous nickel, are used, this shortens the distance between the active material and
the current collector, thereby making the moving distance of electrons shorter, and
the current collecting area is increased. As a result, high performance batteries of
small electrical resistance are obtained.
Furthermore, since the separator 46 and the ion permeable current
collector 44 exist relatively plentifully in the inside of the battery cell, the filling
amount of the cathode and anode active materials 40, 42 per unit volume is small,
thereby making it possible to hold a plenty of electrolytic solution within the cell.

Accordingly, the dry out phenomenon, in which a solid-liquid reaction (a cell
reaction) will no longer occur due to electrolytic solution depletion, is unlikely to
occur.
Referring now to Figure 8, is shown an example of a second embodiment
of the high power type three-dimensional battery in accordance with the present
invention. In the present embodiment, a plurality of basic units (for example, four
basic units in Fig. 8) are incorporated in parallel to constitute a battery. As a basic
unit 52, a bellows-shaped basic unit as described in the first embodiment is
produced. Four basic units 52 are loaded in parallel between the cathode current
collector 48 and the anode current collector 50 for constitution of a battery.
Referring to Figure 9, is shown an example of a third embodiment of the
high power type three-dimensional battery in accordance with the present invention.
In the present embodiment, a plurality of basic units (for example, four basic units
in Fig. 9) are incorporated in parallel in the form of layers. A plurality of such layers
(for example, four layers in Fig. 9) are placed one upon the other to constitute a
battery. As the basic unit 52, a bellows-shaped basic unit as described in the first
embodiment is produced. Four basic units 52 are loaded in parallel into a battery
cell in the form of layers. Four such layers are placed one upon the other through
respective dividing walls 54 to constitute a battery. If cells are placed in series one
upon the other, this provides a high voltage battery. As the material of the dividing
wall 54, a nickel metal plate, a nickel metal foil, carbon, nickel-plated iron,
nickel-plated stainless steel, nickel-plated carbon, or the like may be used.
As in the second and third embodiments, the arrangement that a plurality
of bellows-shaped basic units are loaded in a battery cell makes it possible to easily
achieve an increase in battery size and, in addition, since there are no welds
causing the electrical resistance to increase, this prevents the drop in performance
due to the increase in size. Additionally, it becomes possible to reduce production
cost and production time.
Referring to Figure 10, is shown an example of a fourth embodiment of the
high power type three-dimensional battery in accordance with the present invention.
In the present embodiment, a battery is constituted of a single basic unit and, in
comparison with the first embodiment, the present embodiment employs a thicker

active material in order to provide a battery with a great volume energy density.
For example, for the case of nickel-hydrogen secondary batteries, 2000 g of nickel
hydroxide powders, 200 g of EVA resin, and 300 g of electrically conductive filler
(carbon black and carbon fibers) are mixed together. Thereafter, the mixture is
subjected to pressurized forming by application of a pressure of 0.1 MPa to form a
plate-like cathode active material 40 (100 mm x 30 mm x 12 mm (thickness)).
Likewise, for example, 6000 g of hydrogen-occluding alloy powder, 200 g of EVA
resin, and 300 g of electrically conductive filler (carbon black and carbon fibers) are
mixed together. Thereafter, the mixture is subjected to pressurized forming by
application of a pressure of 0.1 MPa to form a plate-like anode active material 42
(100 mm x 30 mm x 8 mm (thickness)). As in the first embodiment, any surface(s)
(for example, four surfaces) of each of the cathode and anode active materials 40,
42 are coated with the ion permeable current collector 44, after which
bellows-shaped cathode active materials 40 and anode active materials 42 are
incorporated so that they face each other across the separator 46. The basic unit
thus prepared is loaded, together with an electrolytic solution, between the cathode
current collector 48 and the anode current collector 50 in the battery cell for
constitution of a battery.
If, as described above, the thickness of active material is increased, this
relatively reduces the ratio of the separator 46 and the ion permeable current
collector 44. As a result, despite the drop in output power per volume it becomes
possible to obtain a battery having a high volume energy density. On the other
hand, if the thickness of active material is reduced because high power battery
performance is required in the aforesaid embodiments, this relatively increases the
ratio of the separator 46 and the ion permeable type current collector 44. As a
result, despite the drop in volume energy density it becomes possible to obtain a
high power battery. As described above, any changes to the battery specification
can be made just by increasing or decreasing the thickness of active material and
the like, and desired battery specifications are obtained easily.
Referring to Figures 11 and 12, is shown an example of a fifth embodiment
of the high power type three-dimensional battery in accordance with the present
invention. In a bellows-shaped unit (a basic unit) of the present embodiment

comprising cathode and anode active materials which are so incorporated as to face
each other across a separator, the number of cathode active materials is greater
than the number of anode active materials by one, or vice versa, and either the
cathode active materials or the anode active materials, whichever are greater in
number, are disposed at each end of the basic unit.
Referring to Figure 11, is shown a basic unit by way of example in which
anode active materials 42 are disposed on both sides of a cathode active material
40, with a bellow-shaped separator 46 sandwiched between the cathode active
material 40 and each anode active material 42. Other structures and operations
are the same as the first embodiment. In addition, the bellows-shaped basic unit of
the present embodiment may be produced by adequately selecting a structure
ranging from a minimum structure shown in Figure 11 to a structure provided with
any arbitrary number of basic units.
When achieving an increase in size by loading bellows-shaped basic units
(as shown in Fig. 11) in parallel, it is necessary to load them in the way as shown in
Figure 12.
Referring to Figures 13 to 17, is shown examples of a sixth embodiment of
the high power type three-dimensional battery in accordance with the present
invention. In the sixth embodiment, an ion permeable current collector is disposed
at a certain position in cathode active material and anode active material. Figure
13 shows an example in which three surfaces of a plate-like anode active material
42 are covered with an ion permeable current collector 44, indicating that any
surface(s) of the cathode active material 40 and anode active material 42 can be
coated with the ion permeable current collector 44. Figures 14-17 each show an
example in which an ion permeable current collector 44 is disposed on a surface of
the anode active material 42 and inside thereof, indicating that that the ion
permeable current collectors 44 can be disposed at any place(s) of the cathode
active material 40 and anode active material 42. Even in the case where an ion
permeable current collector is disposed inside the cathode and anode active
materials, the distance between the active material and the current collector is
reduced and the moving distance of electrons is reduced. The current collector
area increases and a high performance battery having a small electric resistance is

obtained.
Other structures and operations are the same as the first to fifth
embodiments.
INDUSTRIAL APPLICABILITY
The present invention, since it is constructed in the way as describe
above, makes it possible to reduce the number of component parts required at the
time of assembling a battery. Therefore, the present invention provides a
three-dimensional battery and its electrode structure requiring less assembly time
and less assembly cost. The present invention further provides a three-dimensional
battery capable of being increased easily in size and of producing high output
powers without undergoing a drop in performance due to the incerase in size.

WE CLAIM :
1. A three-dimensional battery with an electrode structure comprising a
battery unit having two vessels connected with a separator interposed
therebetween, a forming product in powder, particle or plate shape of active
material in an electrolytic solution filled in one of the vessels to discharge the
electron, and a forming product in powder, particle or plate shape of active
material in an electrolytic solution filled in the other vessel to absorb the electron,
the three-dimensional battery having either a configuration which consists
of a single battery unit in which a current collector in contact with the active
material is provided in each of the two vessels, or
a configuration which consists of plural battery units layered one upon the
other through respective dividing walls, in which vessels situated on both ends
are each provided with a current collector in contact with an active material,
characterized in that the active material cured by adding an electrically
conductive filler and a resin to a material capable of causing a cell reaction, is so
produced as to be formed integrally with the separator.
2. A three-dimensional battery with an electrode structure comprising a
battery unit having two vessels connected with a separator interposed
therebetween, a forming product in powder, particle or plate shape of active
material in an electrolytic solution filled in one of the vessels to discharge the
electron, and a forming product in powder, particle or plate shape of active
material in an electrolytic solution filled in the other vessel to absorb the electron,
the three-dimensional battery having a configuration which consists of
plural battery units layered one upon the other through respective dividing walls,
in which vessels situated on both ends are each provided with a current collector
in contact with the active material,
characterized in that the active material cured by adding an electrically
conductive filler and a resin to a material capable of causing a cell reaction, is so
produced as to be formed integrally with the dividing wall.

3. The three-dimensional battery with the electrode structure as claimed in
claim 2, wherein the dividing wall is planar or the dividing wall has projected
portions in needle, plate, wave, particle, or the like shape.
4. The three-dimensional battery with the electrode structure as claimed in
claim 2 or 3, wherein the dividing wall is provided with a cooling structure which
has refrigerant flowing path inside.
5. A three-dimensional battery with an electrode structure comprising a
battery unit having two vessels connected with a separator interposed
therebetween, a forming product in powder, particle or plate shape of active
material in an electrolytic solution filled in one of the vessels to discharge the
electron, and a forming product in powder, particle or plate shape of active
material in an electrolytic solution filled in the other vessel to absorb the electron,
the three-dimensional battery having either a configuration which consists
of a single battery unit in which a current collector in contact with the active
material is provided in each of the two vessels, or
a configuration which consists of plural battery units layered one upon the
other through respective dividing walls, in which vessels situated on both ends
are each provided with a current collector in contact with an active material,
characterized in that the active material cured by adding an electrically
conductive filler and a resin to a material capable of causing a cell reaction, is so
produced as to be formed integrally with the current collector.
6. The three-dimensional battery with the electrode structure as claimed in
claim 5, wherein the current collector in contact with the active material is
provided with an additional ion permeable current collector which has voids
therein, which permits passage of ions, and which has electrical conductive
properties.

7. The three-dimensional battery with the electrode structure as claimed in
claim 5 or 6, wherein the current collector is planar or the current collector has
projected portions in needle, plate, wave, particle, or the like shape.
8. The three-dimensional battery with the electrode structure as claimed in
claim 5, 6 or 7, wherein the current collector is provided with a cooling structure
which has refrigerant flowing path inside.
9. A three-dimensional battery with an electrode structure comprising a
battery unit having two vessels connected with a separator interposed
therebetween, a forming product in powder, particle or plate shape of active
material in an electrolytic solution filled in one of the vessels to discharge the
electron, and a forming product in powder, particle or plate shape of active
material in an electrolytic solution filled in the other vessel to absorb the electron,
the three-dimensional battery having either a configuration which consists
of a single battery unit in which a current collector in contact with the active
material is provided in each of the two vessels, or
a configuration which consists of plural battery units layered one upon the
other through respective dividing walls, in which vessels situated on both ends
are each provided with a current collector in contact with the active material,
characterized in that the active material cured by adding an electrically
conductive filler and a resin to a material capable of causing a cell reaction, is so
produced as to be formed integrally with at least any two of a separator, a
dividing wall, and a current collector.
10. The three-dimensional battery with the electrode structure as claimed in
any one of claims 1 to 9, wherein an electrically conductive filler which is
added to the active material is made of either any one selected from the

group consisting of carbon fibers, nickel-plated carbon fibers, nickel-plated
inorganic fibers made of silica, alumina and the like, nickel - plated organic
fibers, nickel plated foil made of an inorganic substance such as mica, carbon
particles, nickel-plated carbon particles, nickel in fiber shape, nickel particles,
and nickel foil or any combination thereof.
11. The three-dimensional battery with the electrode structure as claimed in
any one of claims 1 to 10, wherein the active material is at least any one of
powder, particle, plate, scale, cylindrical rod, polygonal cylindrical rod, sphere,
dice, cube, and or amorphous particle shape.
12. A method for producing a three-dimensional battery with an electrode
structure comprising a battery unit having two vessels connected with a
separator interposed therebetween, a forming product in powder, particle or plate
shape of active material in an electrolytic solution filled in one of the vessels to
discharge the electron, and a forming product in powder, particle or plate shape
of active material in an electrolytic solution filled in the other vessel to absorb the
electron,
the three-dimensional battery having either a configuration which consists
of a single battery unit in which a current collector in contact with the active
material is provided in each of the two vessels, or
a configuration which consists of plural battery units layered one upon the
other through respective dividing walls, in which vessels situated on both ends
are each provided with a current collector in contact with the active material,
characterized in that the active material cured by adding an electrically
conductive filler and a resin to a material capable of causing a cell reaction, and
a separator are combined together and formed integrally with each other in one
piece.

13. A method for producing a three-dimensional battery with an electrode
structure comprising a battery unit having two vessels connected with a
separator interposed therebetween, a forming product in powder, particle or plate
shape of active material in an electrolytic solution filled in one of the vessels to
discharge the electron, and a forming product in powder, particle or plate shape
of active material in an electrolytic solution filled in the other vessel to absorb the
electron,
the three-dimensional battery having a configuration which consists of
plural battery units layered one upon the other through respective dividing walls,
in which vessels situated on both ends are each provided with a current collector
in contact with the active material,
characterized in that an active material cured by adding an electrically
conductive filler and a resin to a material capable of causing a cell reaction, and
a dividing wall are combined together and formed integrally with each other in
one piece.
14. A method for producing a three-dimensional battery with an electrode
structure comprising a battery unit having two vessels connected with a
separator interposed therebetween, a forming product in powder, particle or plate
shape of active material in an electrolytic solution filled in one of the vessels to
discharge the electron, and a forming product in powder, particle or plate shape
of active material in an electrolytic solution filled in the other vessel to absorb the
electron,
the three-dimensional battery having either a configuration which consists
of a single battery unit in which a current collector in contact with the active
material is provided in each of the two vessels, or
a configuration which consists of plural battery units layered one upon the
other through respective dividing walls, in which vessels situated on both ends

are each provided with a current collector in contact with the active material,
characterized in that an active material cured by adding an electrically
conductive filler and a resin to a material capable of causing a cell reaction, and
a current collector are combined together and formed integrally with each other
in one piece.
15. The method for producing the three-dimensional battery with the electrode
structure as claimed in claim 14, wherein the current collector in contact
with the active material is provided with an additional ion permeable current
collector which has voids therein, which permits passage of ions, and which has
electrical conductive properties.
16. The method for producing the three-dimensional battery with the electrode
structure as claimed in claim 15, wherein the ion permeable current collector is
made of at least any one of a nickel metal mesh, carbon fibers, a mesh-like body
made of nickel-plated iron, nickel-plated stainless steel and the like, foamed
nickel metal, nickel-plated foamed resin, nickel-plated carbon fibers, nickel-
plated inorganic fibers made of silica, alumina and the like, nickel-plated organic
fibers, nickel-plated felt, and nickel-plated foil made of an inorganic substance
such as mica.
17. A method for producing a three-dimensional battery with an electrode
structure comprising a battery unit having two vessels connected with a
separator interposed therebetween, a forming product in powder, particle or plate
shape of active material in an electrolytic solution filled in one of the vessels to
discharge the electron, and a forming product in powder, particle or plate shape
of active material in an electrolytic solution filled in the other vessel to absorb the
electron,
the three-dimensional battery having either a configuration which consists

of a single battery unit in which a current collector in contact with the active
material is provided in each of the two vessels, or
a configuration which consists of plural battery units layered one upon the
other through respective dividing walls, in which vessels situated on both ends
are each provided with a current collector in contact with the active material,
characterized in that an active material cured by adding an electrically
conductive filler and a resin to a material capable of causing a cell reaction, and
at least any two of a separator, a dividing wall, and a current collector are
combined together and formed integrally with one another in one piece.
18. The method for producing the three-dimensional battery with the electrode
structure as claimed in any one of claims 12 to 17, wherein when combining an
active material with a separator, a dividing wall, and a current collector to form
them into one piece, pressurized forming and / or forming by a resin mixed with
an electrically conductive filler are carried out.
19. The method for producing the three-dimensional battery with the electrode
structure as claimed in any one of claims 12 to 18, wherein the active material
has at least any one of powder, particle, plate, scale, cylindrical rod, polygonal
cylindrical rod, sphere, dice, cube, and amorphous particle shape.

When producing an electrode for use in a three-
dimensional battery, an active material (12, 14) is combined with
at least one of a separator (10), a dividing wall (16), and a
current collector (18, 20) for simultaneous formation. Both the
dividing wall (16) and the current collector (18, 20) are planar or
are so formed as to have projected portions in needle, plate,
wave, particle, or the like form. Both the dividing wall (16) and
the current collector (18, 20) may be provided with a cooling
structure. As an additional current collector, an ion permeable
current collector (22), which has voids therein, permits passage
of ions, and exhibits electrical conductive properties, is
provided.

Documents:

348-KOLNP-2004-CORRESPONDENCE 1.1.pdf

348-KOLNP-2004-CORRESPONDENCE.pdf

348-KOLNP-2004-FORM 27 1.1.pdf

348-KOLNP-2004-FORM 27.pdf

348-KOLNP-2004-FORM-27.pdf

348-kolnp-2004-granted-abstract.pdf

348-kolnp-2004-granted-assignment.pdf

348-kolnp-2004-granted-claims.pdf

348-kolnp-2004-granted-correspondence.pdf

348-kolnp-2004-granted-description (complete).pdf

348-kolnp-2004-granted-drawings.pdf

348-kolnp-2004-granted-examination report.pdf

348-kolnp-2004-granted-form 1.pdf

348-kolnp-2004-granted-form 18.pdf

348-kolnp-2004-granted-form 3.pdf

348-kolnp-2004-granted-form 5.pdf

348-kolnp-2004-granted-gpa.pdf

348-kolnp-2004-granted-letter patent.pdf

348-kolnp-2004-granted-reply to examination report.pdf

348-kolnp-2004-granted-specification.pdf


Patent Number 227601
Indian Patent Application Number 348/KOLNP/2004
PG Journal Number 03/2009
Publication Date 16-Jan-2009
Grant Date 14-Jan-2009
Date of Filing 15-Mar-2004
Name of Patentee KAWASAKI JUKOGYO KABUSHIKI KAISHA
Applicant Address 1 - 1, HIGASHIKAWASAKI - CHO 3 - CHOME, CHUO -KU, KOBE - SHI, HYOGO 650 - 8670
Inventors:
# Inventor's Name Inventor's Address
1 TSUTSUMI KAZUO 3 - 25 - 10, KITAYAMADAI, NISHI - KU, KOBE - SHI, HYOGO 651 - 2215
2 NISHIMURA KAZUYA 5 - 6 - 3A - 325, AOYAMADAI, TARUMI - KU, KOBE - SHI, HYOGO 655 - 0873
3 MITSUDA SUSUMU 98 - 97, TAMAKI, SANNANCHO HIKAMI - GUN, HYOGO 669 - 3122
4 TANIGAWA TAKAHITO 107 - 201, ANJOJIMACHI, MATSUYAMA - SHI, EHIME 791 - 8006
PCT International Classification Number H01M 10/28, 4/32
PCT International Application Number PCT/JP02/09409
PCT International Filing date 2002-09-13
PCT Conventions:
# PCT Application Number Date of Convention Priority Country
1 2001 - 284491 2001-09-19 Japan
2 2001 - 284489 2001-09-19 Japan