Title of Invention	STORAGE BATTERY ELECTRODES WITH INTEGRAL CONDUCTORS
Abstract	A battery cell has a plurality of first and second electrodes of opposite polarities that are interleaved. Each of the first and second electrodes is a sheet of non-woven fabric having a first edge from which a tab projects, and a second edge transverse to and substantially longer than the first edge. The non-woven fabric is coated with a metal in a manner that forms a strip along the second edge which has a greater electrical conductivity than areas more remote from the second edge. The strip extends along the tab. A first terminal is electrically connected to the strip along the tabs of the first electrodes, and a second terminal is electrically connected to the strip along the tabs of the second electrodes.

Title of Invention

STORAGE BATTERY ELECTRODES WITH INTEGRAL CONDUCTORS

Abstract

A battery cell has a plurality of first and second electrodes of opposite polarities that are interleaved. Each of the first and second electrodes is a sheet of non-woven fabric having a first edge from which a tab projects, and a second edge transverse to and substantially longer than the first edge. The non-woven fabric is coated with a metal in a manner that forms a strip along the second edge which has a greater electrical conductivity than areas more remote from the second edge. The strip extends along the tab. A first terminal is electrically connected to the strip along the tabs of the first electrodes, and a second terminal is electrically connected to the strip along the tabs of the second electrodes.

Full Text	WO 2007/061624 PCT/US2006/043346 STORAGE BATTERY ELECTRODES WITH INTEGRAL CONDUCTORS Cross-Reference to Related Applications Not Applicable Statement Regarding Federally Sponsored Research or Development Not Applicable Background of the Invention 1. Field of the Invention [0001] This invention relates generally to the structure of electrochemical storage batteries, and more particularly, to a novel and improved electrode plate for such batteries. 2. Description of the Related Art [0002] Typically, storage batteries of the electrochemical type have one or more cells which include a plurality of first electrodes of one polarity interleaved in a spaced apart manner with a plurality of second electrodes of the opposite polarity. Separate terminals interconnect the electrodes of each polarity, usually to a terminal post, so that two terminals of opposite polarity are provided for each cell. [0003] U. S. Patent No. 5,158,842 discloses the basic structure of a storage battery having a plurality of interleaved electrode plates of opposite polarities. Each of the plates has a generally rectangular main section that forms an active region of the electrode with a tab projecting outward from one corner of the main section. The tabs -1- WO 2007/061624 PCT/US2006/043346 of the electrode plates of one polarity are aligned along one side of the battery, while the tabs on the opposite polarity plates are aligned on the other side of the battery. The respective tabs of the plates of the same polarity are electrically connected, such as by welding, to the body of a terminal that has a connection post. [0004] One type of electrode plate comprised a flexible fiber plaque that was suitable for active material loaded electrodes, such as used in nickel-cadmium and nickel-iron battery systems. A common fibrous plaque was made of compacted, intermingled fine fibers reactively diffused with nickel by conventional plating processes. Prior batteries had plaques that often were formed by conductive fibers, such as iron wool, however non-conductive fibers also were used. The fibers were randomly oriented in the length, width and thickness directions of the plaque and are diffusion bonded with nickel at their contact points. The resultant electrode had pores into which the active material of the battery was introduced during subsequent assembly steps. [0005] As shown in Figure 1, a typical previous electrode 10 was rectangular - having one edge that was significantly greater than another orthogonal edge. The electrode 10 has a sheet-like body 11 comprising a main, or active, region 12 and a tab 16. The main region 12 had a uniform electrical conductivity. The tab 16 projected from the longer edge of the main section 12 and due to the electroplating process that tab had a portion 14 with greater density of metal. That portion 14 enabled a metal contact tab 18 to be welded to the electrode body 11. In the final battery, a battery terminal was welded or otherwise electrically connected to the contact tabs 18 of the electrodes 10 of the same polarity, thereby connecting those electrodes together. -2- WO 2007/061624 PCT/US2006/043346 [0006] Certain battery installations dictated that the terminals be placed along the shorter edge of the electrode with the edge extending perpendicularly there from having a significantly greater length. However, it was discovered that in this orientation the effective resistance in the portion of the electrode remote from the tab was significantly greater than the portion of the electrode adjacent the tab. Thus, the more distant portion of the electrode was less effective than the portion closer to the tab. SUMMARY OF THE INVENTION [0007] The present invention provides a novel and improved battery cell and electrodes for that cell. [0008] The battery cell is formed by a plurality of first electrodes of one polarity interleaved with a plurality of second electrodes of an opposite polarity. Each of the first and second electrodes comprises a sheet of non-woven fabric having a first edge from which a portion of the non-woven fabric projects forming a tab, and having a second edge that is transverse to and preferably substantially longer than the first edge. The non-woven fabric has metal deposited thereon in a manner that forms a strip along the second edge which has a greater electrical conductivity than metal plated areas of the sheet that are remote from the second edge. This strip continues to extend along the tab. [0009] A first terminal is attached to the tabs of the first electrodes in electrical contact with the strip along each tab. A second terminal is attached in electrical contact with the strip along the tabs on the second electrodes. -3- WO 2007/061624 PCT/US2006/043346 [0010] In a preferred embodiment, the non-woven fabric is a needle punched felt made of polypropylene fibers. The needle punched felt is coated with the metal. Preferably, the non-woven fabric is electroplated with the metal, wherein a greater density of the metal is deposited along the second edge. BRIEF DESCRIPTION OF THE DRAWINGS [0011] FIGURE 1 is a plane view of an electrode plate from a previous battery; [0012] FIGURE 2 is a cutaway perspective view of a battery containing unique electrodes according to the present invention; and [0013] FIGURE 3 is a perspective view of one of those electrodes. DETAILED DESCRIPTION OF THE INVENTION [0014] With initial reference to Figure 2, a battery 20 according to the present invention has a single cell 22, however it should be understood that the present concepts can be utilized in multiple cell batteries. The battery cell 22 comprises a plurality of interleaved first and second electrodes 24 and 26 contained within a housing 28. The first and second electrodes 24 and 26 have opposite electrical polarities and the number of them varies as is necessary to provide the desired capacity of the battery 20. The electrodes 24 and 26 are interleaved in a parallel, spaced apart configuration. An active material of the battery is placed into the pores of the electrodes. [0015] When referenced to Figure 3 each of the first and second electrodes 24 and 26 is formed from a sheet of a non-woven material, such as needle punched felt made of polypropylene fibers. Needle punched fabrics are well known for a variety of uses -4- WO 2007/061624 PCT/US2006/043346 and are made by initially carding selected fibers into a web which then is layered up to a desired required thickness. The resultant web is passed through a needle bed that comprises thousands of barbed needles set in a plate which goes up and down with respect to the web. That action pushes the needles through the fibers which has the effect of entangling the fibers. The web then is calendered to achieve the final thickness. [0016] Fabrication of both types of electrodes 24 and 26 from the non-woven web material initially involves electroless plating the material with metal, such as nickel, which results in relatively thin metal coating on the web fibers. With a conductive coating on the fibers, the material then is electroplated to increase the thickness of the metal. For example, the needle punched felt web can be provided in a long roll from which numerous individual electrodes 24 and 26 are later cut. After the electroless plating, the web material is unwound from the roll and fed through an electroplating apparatus. The electroplating provides a rather uniformly dense metal coating on the major portion of the web, however the metal coating along the edges has a greater density than elsewhere. Therefore, the edge regions have a higher electrical conductivity. [0017] The metal coated felt material then is impregnated with a metal consistent with the type of battery in which the electrode will be used. In a nickel-cadmium battery system, for example, cadmium is embedded into the pores of a felt web for the negative, first electrodes 24; and additional nickel is embedded in the pores of another felt web for the positive, second electrodes 26. However, a skilled artisan will recognize that different metals are employed to form other types of batteries. [0018] After the metal has been deposited on the non-woven felt, individual electrodes are punched or otherwise cut from the material. This process produces an -5- WO 2007/061624 PCT/US2006/043346 electrode having a large porous surface area. With continuing reference to Figure 3, each electrode 30 thereby comprises a generally rectangular sheet 31 of the non-woven, metal plated material, however a sheet of another shape may be created. The sheet 31 has a first edge 32 extending along its narrower dimension and has a longer second edge ^ * 34 perpendicular to the first edge 32. A tab 36 projects outwardly from the first edge 32 at a corner where the first and second edges would otherwise intersect and the second edge 34 continues to extend along the tab. In forming the individual electrodes 30 from the larger body that was electroplated, the region with the greater density metal coated fibers forms a strip 38 along the second edge 34 of the electrode sheet 31. That strip 38 extends the entire length along the second edge including the tab 36. This strip 38 acts as a conductor linking the tab 36 to the active remote regions of the electrode thereby providing better utilization of the active material over the entire surface area of the electrode. [0019] This process produces a plurality of the first and second electrodes 24 and 26 that then are assembled into the battery cell 22 by interleaving the two types of electrodes as seen in Figure 2. In this assembly, the tabs 36 of the first electrodes 24 oriented along one side while the tabs 36 on the second electrodes 26 are oriented along the opposite side. A negative, first electrical terminal 40 is inserted between two adjacent first electrodes 24 in the middle of the electrode assembly, and the tabs 36 of first electrodes 24 are bent inward against each other and against opposite side surfaces of a first electrical terminal 40. Therefore, the upper sections of the tabs 36 on adjacent first electrodes are abutting and one tab on each side abuts the first electrical terminal 40. While being held in this position those tabs 36 are welded to one another and to the -6- WO 2007/061624 PCT/US2006/043346 first terminal 40. Specifically the more densely metalized strip 38 on each tab provides a surface for welding to the terminal. A positive, second electrical terminal 42 is connected to the tabs 36 on the second electrodes 26 in the same manner as described with respect to the first terminal 40. Other techniques for electrically connecting the tabs 36 of the two electrodes 24 and 26 to the respective terminal 40 or 42, such as brazing or mechanical fastening by a bolt for example, can be employed.. [0020] The sub-assembly of the plurality of first and second electrodes 24 and 26 and the two terminals 40 and 42 then is placed into the housing 28, which is sealed so that only the upper portion of each terminal projects through the housing. [0021] The foregoing description was primarily directed to a preferred embodiment of the invention. Although some attention was given to various alternatives within the scope of the invention, it is anticipated that one skilled in the art will likely realize additional alternatives that are now apparent from disclosure of embodiments of the invention. Accordingly, the scope of the invention should be determined from the following claims and not limited by the above disclosure. -7- WO 2007/061624 PCT/US2006/043346 CLAIMS 1. A battery cell comprising: first electrodes of one polarity; second electrodes of opposite polarity interleaved with the first electrodes; wherein each of the first and second electrodes comprises a sheet of a non-woven fabric having a first edge from which a portion of the non-woven fabric projects forming a tab, and a second edge transverse to the first edge, the non-woven fabric is coated with a metal wherein the metal is deposited so as to form a strip along the second edge which has a greater electrical conductivity than metal coated areas of the sheet more remote from the second edge, the strip extending along the tab; a first terminal attached to each tab of the first electrodes and electrically connected to the strip along that tab; and a second terminal attached to each tab of the second electrodes and electrically connected to the strip along the tab of the second electrodes. 2. The battery cell as recited in claim 1 wherein the second edge of each of the first and second electrodes is substantially longer than the first edge. 3. The battery cell as recited in claim 1 wherein the non-woven fabric comprises polypropylene fibers. 4. The battery cell as recited in claim 1 wherein the non-woven fabric comprises a needle punched material. -8- WO 2007/061624 PCT/US2006/043346 5. The battery cell as recited in claim 1 wherein the non-woven fabric is electroplated with the metal, wherein a greater density of the metal is deposited along the second edge. 6. The battery cell as recited in claim 1 further comprising a first weld electrically connecting the strip along the tab of each first electrode to the first terminal, and a second weld electrically connecting the strip along the tab of each second electrode to the second terminal. 7. The battery cell as recited in claim 1 wherein tabs of adjacent first electrodes abut each other and at least one of those tabs abuts the first terminal. 8. The battery cell as recited in claim 7 wherein the tabs of the first electrodes are held together and to the first terminal by at least one of a weld joint, a braze joint, and a mechanical fastener. 9. The battery cell as recited in claim 1 wherein the first terminal is located between two of the tabs on the first electrodes, and the tabs of adjacent first electrodes on one side of the first terminal abut each other and at least one of those tabs abuts a surface of the first terminal, and other tabs of adjacent first electrodes on another side of the first terminal abut each other and at least one of those other tabs abuts another surface of the first terminal. -9- WO 2007/061624 PCT/US2006/043346 10. The battery cell as recited in claim 1 wherein tabs of adjacent first electrodes abut each other and at least one of those tabs abuts the first terminal; and tabs of adjacent second electrodes abut each other and at least one of those tabs on the second electrodes abuts the second terminal. 11. The battery cell as recited in claim 10 wherein the tabs of the first electrodes are held together and to the first terminal by at least one of a weld joint, a braze joint, and a mechanical fastener; and the tabs of the second electrodes are held together and to the second terminal by at least one of a weld joint, a braze joint, and a mechanical fastener. 12. The battery cell as recited in claim 1 wherein: the first terminal is located between two of the tabs on the first electrodes, and tabs of adjacent first electrodes on one side of the first terminal abut each other and at least one of those tabs abuts a surface of the first terminal, and other tabs of adjacent first electrodes on another side of the first terminal abut each other and at least one of those other tabs abuts another surface of the first terminal; and the second terminal is located between two of the tabs of the second electrodes, and the tabs of adjacent second electrodes on one side of the second terminal abut each other and at least one of those tabs abuts a surface of the second terminal, and other tabs of adjacent second electrodes on another side of the second terminal abut each other and at least one of those other second electrode tabs abuts another surface of the second terminal. -10- WO 2007/061624 PCT/US2006/043346 13. An electrode for a battery cell, said electrode comprising a sheet of non-woven fabric having a first edge from which a portion of the non-woven fabric projects forming a tab, and a second edge transverse to and substantially longer than the first edge, the non-woven fabric being coated with a metal, wherein the metal is deposited so as to form a strip that extends along the second edge and that has a greater electrical conductivity than metal coated areas of the sheet more remote from the second edge, the strip extending along the tab. 14. The electrode as recited in claim 13 wherein the non-woven fabric comprises polypropylene fibers. 15. The electrode as recited in claim 13 wherein the non-woven fabric comprises a needle punched material. 16. The electrode as recited in claim 13 wherein the non-woven fabric is electroplated with the metal, wherein a greater density of the metal is deposited in the strip along the second edge. -11- A battery cell has a plurality of first and second electrodes of opposite polarities that are interleaved. Each of the first and second electrodes is a sheet of non-woven fabric having a first edge from which a tab projects, and a second edge transverse to and substantially longer than the first edge. The non-woven fabric is coated with a metal in a manner that forms a strip along the second edge which has a greater electrical conductivity than areas more remote from the second edge. The strip extends along the tab. A first terminal is electrically connected to the strip along the tabs of the first electrodes, and a second terminal is electrically connected to the strip along the tabs of the second electrodes.

Full Text

WO 2007/061624

PCT/US2006/043346

STORAGE BATTERY ELECTRODES
WITH INTEGRAL CONDUCTORS
Cross-Reference to Related Applications
Not Applicable
Statement Regarding Federally
Sponsored Research or Development
Not Applicable
Background of the Invention
1. Field of the Invention
[0001] This invention relates generally to the structure of electrochemical storage
batteries, and more particularly, to a novel and improved electrode plate for such
batteries.
2. Description of the Related Art
[0002] Typically, storage batteries of the electrochemical type have one or more
cells which include a plurality of first electrodes of one polarity interleaved in a spaced
apart manner with a plurality of second electrodes of the opposite polarity. Separate
terminals interconnect the electrodes of each polarity, usually to a terminal post, so that
two terminals of opposite polarity are provided for each cell.
[0003] U. S. Patent No. 5,158,842 discloses the basic structure of a storage
battery having a plurality of interleaved electrode plates of opposite polarities. Each
of the plates has a generally rectangular main section that forms an active region of the
electrode with a tab projecting outward from one corner of the main section. The tabs
-1-

WO 2007/061624 PCT/US2006/043346
of the electrode plates of one polarity are aligned along one side of the battery, while
the tabs on the opposite polarity plates are aligned on the other side of the battery. The
respective tabs of the plates of the same polarity are electrically connected, such as by
welding, to the body of a terminal that has a connection post.
[0004] One type of electrode plate comprised a flexible fiber plaque that was suitable
for active material loaded electrodes, such as used in nickel-cadmium and nickel-iron
battery systems. A common fibrous plaque was made of compacted, intermingled fine
fibers reactively diffused with nickel by conventional plating processes. Prior batteries
had plaques that often were formed by conductive fibers, such as iron wool, however
non-conductive fibers also were used. The fibers were randomly oriented in the length,
width and thickness directions of the plaque and are diffusion bonded with nickel at
their contact points. The resultant electrode had pores into which the active material of
the battery was introduced during subsequent assembly steps.
[0005] As shown in Figure 1, a typical previous electrode 10 was rectangular - having
one edge that was significantly greater than another orthogonal edge. The electrode 10
has a sheet-like body 11 comprising a main, or active, region 12 and a tab 16. The main
region 12 had a uniform electrical conductivity. The tab 16 projected from the longer
edge of the main section 12 and due to the electroplating process that tab had a portion 14
with greater density of metal. That portion 14 enabled a metal contact tab 18 to be welded
to the electrode body 11. In the final battery, a battery terminal was welded or otherwise
electrically connected to the contact tabs 18 of the electrodes 10 of the same polarity,
thereby connecting those electrodes together.
-2-

WO 2007/061624 PCT/US2006/043346
[0006] Certain battery installations dictated that the terminals be placed along the
shorter edge of the electrode with the edge extending perpendicularly there from having
a significantly greater length. However, it was discovered that in this orientation the
effective resistance in the portion of the electrode remote from the tab was significantly
greater than the portion of the electrode adjacent the tab. Thus, the more distant portion
of the electrode was less effective than the portion closer to the tab.
SUMMARY OF THE INVENTION
[0007] The present invention provides a novel and improved battery cell and
electrodes for that cell.
[0008] The battery cell is formed by a plurality of first electrodes of one polarity
interleaved with a plurality of second electrodes of an opposite polarity. Each of the
first and second electrodes comprises a sheet of non-woven fabric having a first edge
from which a portion of the non-woven fabric projects forming a tab, and having a
second edge that is transverse to and preferably substantially longer than the first edge.
The non-woven fabric has metal deposited thereon in a manner that forms a strip along
the second edge which has a greater electrical conductivity than metal plated areas of
the sheet that are remote from the second edge. This strip continues to extend along
the tab.
[0009] A first terminal is attached to the tabs of the first electrodes in electrical
contact with the strip along each tab. A second terminal is attached in electrical
contact with the strip along the tabs on the second electrodes.
-3-

WO 2007/061624 PCT/US2006/043346
[0010] In a preferred embodiment, the non-woven fabric is a needle punched felt
made of polypropylene fibers. The needle punched felt is coated with the metal.
Preferably, the non-woven fabric is electroplated with the metal, wherein a greater
density of the metal is deposited along the second edge.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIGURE 1 is a plane view of an electrode plate from a previous battery;
[0012] FIGURE 2 is a cutaway perspective view of a battery containing unique
electrodes according to the present invention; and
[0013] FIGURE 3 is a perspective view of one of those electrodes.
DETAILED DESCRIPTION OF THE INVENTION
[0014] With initial reference to Figure 2, a battery 20 according to the present
invention has a single cell 22, however it should be understood that the present concepts
can be utilized in multiple cell batteries. The battery cell 22 comprises a plurality of
interleaved first and second electrodes 24 and 26 contained within a housing 28. The
first and second electrodes 24 and 26 have opposite electrical polarities and the number
of them varies as is necessary to provide the desired capacity of the battery 20. The
electrodes 24 and 26 are interleaved in a parallel, spaced apart configuration. An active
material of the battery is placed into the pores of the electrodes.
[0015] When referenced to Figure 3 each of the first and second electrodes 24 and
26 is formed from a sheet of a non-woven material, such as needle punched felt made
of polypropylene fibers. Needle punched fabrics are well known for a variety of uses
-4-

WO 2007/061624 PCT/US2006/043346
and are made by initially carding selected fibers into a web which then is layered up
to a desired required thickness. The resultant web is passed through a needle bed that
comprises thousands of barbed needles set in a plate which goes up and down with
respect to the web. That action pushes the needles through the fibers which has the
effect of entangling the fibers. The web then is calendered to achieve the final thickness.
[0016] Fabrication of both types of electrodes 24 and 26 from the non-woven web
material initially involves electroless plating the material with metal, such as nickel,
which results in relatively thin metal coating on the web fibers. With a conductive
coating on the fibers, the material then is electroplated to increase the thickness of the
metal. For example, the needle punched felt web can be provided in a long roll from
which numerous individual electrodes 24 and 26 are later cut. After the electroless
plating, the web material is unwound from the roll and fed through an electroplating
apparatus. The electroplating provides a rather uniformly dense metal coating on the
major portion of the web, however the metal coating along the edges has a greater
density than elsewhere. Therefore, the edge regions have a higher electrical conductivity.
[0017] The metal coated felt material then is impregnated with a metal consistent
with the type of battery in which the electrode will be used. In a nickel-cadmium battery
system, for example, cadmium is embedded into the pores of a felt web for the negative,
first electrodes 24; and additional nickel is embedded in the pores of another felt web
for the positive, second electrodes 26. However, a skilled artisan will recognize that
different metals are employed to form other types of batteries.
[0018] After the metal has been deposited on the non-woven felt, individual
electrodes are punched or otherwise cut from the material. This process produces an
-5-

WO 2007/061624 PCT/US2006/043346
electrode having a large porous surface area. With continuing reference to Figure 3,
each electrode 30 thereby comprises a generally rectangular sheet 31 of the non-woven,
metal plated material, however a sheet of another shape may be created. The sheet 31
has a first edge 32 extending along its narrower dimension and has a longer second edge ^ *
34 perpendicular to the first edge 32. A tab 36 projects outwardly from the first edge 32
at a corner where the first and second edges would otherwise intersect and the second
edge 34 continues to extend along the tab. In forming the individual electrodes 30 from
the larger body that was electroplated, the region with the greater density metal coated
fibers forms a strip 38 along the second edge 34 of the electrode sheet 31. That strip 38
extends the entire length along the second edge including the tab 36. This strip 38 acts
as a conductor linking the tab 36 to the active remote regions of the electrode thereby
providing better utilization of the active material over the entire surface area of the
electrode.
[0019] This process produces a plurality of the first and second electrodes 24 and
26 that then are assembled into the battery cell 22 by interleaving the two types of
electrodes as seen in Figure 2. In this assembly, the tabs 36 of the first electrodes
24 oriented along one side while the tabs 36 on the second electrodes 26 are oriented
along the opposite side. A negative, first electrical terminal 40 is inserted between two
adjacent first electrodes 24 in the middle of the electrode assembly, and the tabs 36 of
first electrodes 24 are bent inward against each other and against opposite side surfaces
of a first electrical terminal 40. Therefore, the upper sections of the tabs 36 on adjacent
first electrodes are abutting and one tab on each side abuts the first electrical terminal
40. While being held in this position those tabs 36 are welded to one another and to the
-6-

WO 2007/061624 PCT/US2006/043346
first terminal 40. Specifically the more densely metalized strip 38 on each tab provides
a surface for welding to the terminal. A positive, second electrical terminal 42 is
connected to the tabs 36 on the second electrodes 26 in the same manner as described
with respect to the first terminal 40. Other techniques for electrically connecting the
tabs 36 of the two electrodes 24 and 26 to the respective terminal 40 or 42, such as
brazing or mechanical fastening by a bolt for example, can be employed..
[0020] The sub-assembly of the plurality of first and second electrodes 24 and 26
and the two terminals 40 and 42 then is placed into the housing 28, which is sealed so
that only the upper portion of each terminal projects through the housing.
[0021] The foregoing description was primarily directed to a preferred embodiment
of the invention. Although some attention was given to various alternatives within the
scope of the invention, it is anticipated that one skilled in the art will likely realize
additional alternatives that are now apparent from disclosure of embodiments of the
invention. Accordingly, the scope of the invention should be determined from the
following claims and not limited by the above disclosure.
-7-

WO 2007/061624 PCT/US2006/043346
CLAIMS
1. A battery cell comprising:
first electrodes of one polarity;
second electrodes of opposite polarity interleaved with the first electrodes;
wherein each of the first and second electrodes comprises a sheet of a non-woven
fabric having a first edge from which a portion of the non-woven fabric projects forming
a tab, and a second edge transverse to the first edge, the non-woven fabric is coated with
a metal wherein the metal is deposited so as to form a strip along the second edge which
has a greater electrical conductivity than metal coated areas of the sheet more remote
from the second edge, the strip extending along the tab;
a first terminal attached to each tab of the first electrodes and electrically
connected to the strip along that tab; and
a second terminal attached to each tab of the second electrodes and electrically
connected to the strip along the tab of the second electrodes.
2. The battery cell as recited in claim 1 wherein the second edge of each of
the first and second electrodes is substantially longer than the first edge.
3. The battery cell as recited in claim 1 wherein the non-woven fabric
comprises polypropylene fibers.
4. The battery cell as recited in claim 1 wherein the non-woven fabric
comprises a needle punched material.
-8-

WO 2007/061624 PCT/US2006/043346
5. The battery cell as recited in claim 1 wherein the non-woven fabric is
electroplated with the metal, wherein a greater density of the metal is deposited along
the second edge.
6. The battery cell as recited in claim 1 further comprising a first weld
electrically connecting the strip along the tab of each first electrode to the first
terminal, and a second weld electrically connecting the strip along the tab of each
second electrode to the second terminal.
7. The battery cell as recited in claim 1 wherein tabs of adjacent first
electrodes abut each other and at least one of those tabs abuts the first terminal.
8. The battery cell as recited in claim 7 wherein the tabs of the first electrodes
are held together and to the first terminal by at least one of a weld joint, a braze joint,
and a mechanical fastener.
9. The battery cell as recited in claim 1 wherein the first terminal is located
between two of the tabs on the first electrodes, and the tabs of adjacent first electrodes
on one side of the first terminal abut each other and at least one of those tabs abuts a
surface of the first terminal, and other tabs of adjacent first electrodes on another side
of the first terminal abut each other and at least one of those other tabs abuts another
surface of the first terminal.
-9-

WO 2007/061624 PCT/US2006/043346
10. The battery cell as recited in claim 1 wherein tabs of adjacent first electrodes
abut each other and at least one of those tabs abuts the first terminal; and tabs of adjacent
second electrodes abut each other and at least one of those tabs on the second electrodes
abuts the second terminal.
11. The battery cell as recited in claim 10 wherein the tabs of the first electrodes
are held together and to the first terminal by at least one of a weld joint, a braze joint, and
a mechanical fastener; and the tabs of the second electrodes are held together and to the
second terminal by at least one of a weld joint, a braze joint, and a mechanical fastener.
12. The battery cell as recited in claim 1 wherein:
the first terminal is located between two of the tabs on the first electrodes, and
tabs of adjacent first electrodes on one side of the first terminal abut each other and at
least one of those tabs abuts a surface of the first terminal, and other tabs of adjacent
first electrodes on another side of the first terminal abut each other and at least one of
those other tabs abuts another surface of the first terminal; and
the second terminal is located between two of the tabs of the second electrodes,
and the tabs of adjacent second electrodes on one side of the second terminal abut each
other and at least one of those tabs abuts a surface of the second terminal, and other tabs
of adjacent second electrodes on another side of the second terminal abut each other and
at least one of those other second electrode tabs abuts another surface of the second
terminal.
-10-

WO 2007/061624 PCT/US2006/043346
13. An electrode for a battery cell, said electrode comprising a sheet of
non-woven fabric having a first edge from which a portion of the non-woven fabric
projects forming a tab, and a second edge transverse to and substantially longer than
the first edge, the non-woven fabric being coated with a metal, wherein the metal is
deposited so as to form a strip that extends along the second edge and that has a
greater electrical conductivity than metal coated areas of the sheet more remote from
the second edge, the strip extending along the tab.
14. The electrode as recited in claim 13 wherein the non-woven fabric
comprises polypropylene fibers.
15. The electrode as recited in claim 13 wherein the non-woven fabric
comprises a needle punched material.
16. The electrode as recited in claim 13 wherein the non-woven fabric is
electroplated with the metal, wherein a greater density of the metal is deposited in the
strip along the second edge.
-11-

A battery cell has a plurality
of first and second electrodes of
opposite polarities that are interleaved.
Each of the first and second electrodes
is a sheet of non-woven fabric having
a first edge from which a tab projects,
and a second edge transverse to and substantially
longer than the first edge. The
non-woven fabric is coated with a metal
in a manner that forms a strip along the
second edge which has a greater electrical
conductivity than areas more remote
from the second edge. The strip extends
along the tab. A first terminal is electrically
connected to the strip along the
tabs of the first electrodes, and a second
terminal is electrically connected to the
strip along the tabs of the second electrodes.

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Patent Number

268816

Indian Patent Application Number

1032/KOLNP/2008

PG Journal Number

39/2015

Publication Date

25-Sep-2015

Grant Date

17-Sep-2015

Date of Filing

10-Mar-2008

Name of Patentee

ACTUANT CORPORATION

Applicant Address

6100 N. BAKER ROAD, GLENDALE, WI

Inventors:

#	Inventor's Name	Inventor's Address
1	BAKER, CHRISTOPHER, A.	939 E. LOBSTER TRAP LANE, TEMPE, AZ 85283
2	MAURIZO, ANTHONY	1358 E. DUNBAR DRIVE, PHONEX, AZ 85042
3	GLEASON, JOHN E.	631 S. BOULDER COURT, GILBERT, AZ 85296

PCT International Classification Number

H01M 4/74, H01M 2/26

PCT International Application Number

PCT/US2006/043346

PCT International Filing date

2006-11-06

PCT Conventions:

#	PCT Application Number	Date of Convention	Priority Country
1	11/282537	2005-11-18	U.S.A.