US3835514A
Expired / Lapsed
US
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Method of making laminated diffusion bonded battery plaques
Assignee: Westinghouse Electric Corp
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Filing: 1973-09-18
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Granted: 1974-09-17
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Expires: 1993-09-18
Abstract
Abstract A laminated, flexible metal fiber electrode plaque is made by (1) providing a first layer of substantially parallel metallic fibers having lengths greater than about 4 inches, (2) placing a second layer of substantially parallel metallic fibers having lengths greater than about 4 inches on top of and contacting the first layer, the second layer having its fibers oriented between 30* and 90* from the fibers of the first layer, (3) placing a third layer of substantially parallel metallic fibers having lengths greater than about 4 inches on top of and contacting the second layer, the third layer having its fibers oriented in the same direction as the fibers of the first layer, (4) metallurgically diffusion bonding the contact points of the fibers between the layers together, to provide, annealed, bonded plaques and bus connectors, (5) coining the annealed, bonded plaque to provide a plaque having a body portion of between 70 and 97 percent porosity and a bus connector portion of up to 70 percent porosity, by pressing the bus connectors into contact with predetermined areas of the plaque and then (6) metallurgically bonding the contact points of the plaque and bus connectors together.
Inventors
- 👤 W Pollack
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-26 22:22
CPC Classifications
B; B23; B23P; B23P13/00; H; H01; H01M; H01M4/00; H01M4/02; H01M4/64; H01M4/70; H01M4/72; H01M4/74; Y; Y02; Y02E; Y02E60/00; Y02E60/10; Y10; Y10T; Y10T29/00; Y10T29/10; Y10T29/49; Y10T29/49801
Claims Analysis
Total Claims: 9
Claim 1
Independent Claim
37 words
The method of claim 1, whereiN the non-oxidizing atmosphere comprises hydrogen gas, the bonding is performed at a temperature between about 800* to 1,300*C and a bus connector and a nickel tab are attached to the electrode.
Claim 2
Independent Claim
338 words
A method of producing strong, flexible, porous, bonded, laminated electrode plaques comprising a body portion consisting of bonded metal fibers free of melt protuberances, comprising the steps of: A. laying a sheet of a plurality of layers each layer consisting of substantially parallel metal fibers selected from the group consisting of iron and steel, having lengths greater than about 4 inches and cross sections between about 1/2 to 5 mil, each layer contacting adjacent layers each layer having its fibers oriented between 30* and 90* from the fibers of adjacent layers, B. heating the layered sheet below the melting point of the fibers in a reducing atmosphere comprising hydrogen gas, to metallurgically solid state bond together the contact points of the fibers within each layer and the fibers of adjacent layers, to form an unmelted bond of diffused metal between the fibers at points of contact, and provide a bonded, laminated plaque of softened fibers free of melt protuberances, and then C. coining the bonded, laminated plaque while the fibers are in a softened condition, to establish additional fiber contacts and provide a plaque having a body portion of between 70 and 97 percent porosity, and then D. attaching bus connectors to predetermined areas of the bonded, laminated plaque to provide a plaque having a body portion of between 70 and 97 percent porosity and a bus connector portion, and then E. re-heating the bonded, laminated plaque below the melting point of the fibers in a reducing atmosphere comprising hydrogen gas, to metallurgically solid state bond together the additional fiber contact points established during coining, to form an unmelted bond of diffused metal between the fibers at points of contact and more firmly attach the bus connectors and provide an unoxidized bonded, laminated electrode plaque of bonded metal fibers free of melt protuberances suitable for coating, and the F. coating the bonded, laminated plaque with a metal coating selected from the group consisting of nickel, cadmuim, copper, and silver, having a thickness from about 0.1 to 1 mil.
Claim 3
Dependent Claim
17 words
The method of claim 3 wherein the bus connector portion is up to about 50 percent porous.
Claim 4
Dependent Claim
30 words
The method of claim 3, wherein a nickel tab is attached to the plaque and the bonding of the fibers is performed at a temperature between about 800* to 1,300*C.
Claim 5
Dependent Claim
34 words
The method of claim 3, wherein the metal fibers have lengths from about 4 to 10 inches and the outside layers of the laminated plaque are oriented in the longitudinal direction of the plaque.
Claim 6
Dependent Claim
34 words
The method of claim 3, wherein in step (A), layers are wound around a first layer, said wound layers having their fibers oriented between 30* and 90* from the fibers of the first layer.
Claim 7
Dependent Claim
110 words
The method of claim 3, wherein, in step (D), bus connectors are pressed into the plaque by i. placing the laminated bonded plaque on top of a flat bottom platen, ii. placing a middle platen on top of the laminated bonded plaque, said middle platen having a predetermined channel cut therethrough, iii. placing bus connectors in the middle platen channel, iv. placing a top platen on top of the middle platen, said top platen having projections which slide through the channel cut through the middle platen and project through the middle platen to cause the bus connectors to contact the plaque and v. pressing the top and bottom platens together.
Claim 8
Independent Claim
349 words
A method of producing strong, flexible, porous, bonded, laminated electrode plaques comprising a body portion consisting of bonded metal fibers free of melt protuberances, comprising the steps of: A. prOviding a first layer comprising substantially parallel metal fibers selected from the group consisting of iron and steel and winding a plurality of layers around the first layer, said wound layers consisting of substantially parallel metal fibers selected from the group consisting of iron and steel, having cross sections between about 1/2 to 5 mil, said wound layers having their fibers oriented between 30* and 90* from the fibers of the first layer, B. heating the layered sheet below the melting point of the fibers in a reducing atmosphere comprising hydrogen gas, to metallurgically solid state bond together the contact points of the fibers within each layer and the fibers of adjacent layers, to form an unmelted bond of diffused metal between the fibers at points of contact, and provide a bonded, laminated plaque of softened fibers free of melt protuberances, and then C. coining the bonded, laminated plaque while the fibers are in a softened condition, to establish additional fiber contacts and provide a plaque having a body portion of between 70 and 97 percent porosity, and then D. attaching bus connectors to predetermined areas of the bonded, laminated plaque to provide a plaque having a body portion of between 70 and 97 percent porosity and a bus connector portion, and then E. re-heating the bonded, laminated plaque below the melting point of the fibers in a reducing atmosphere comprising hydrogen gas, to metallurgically solid state bond together the additional fiber contact points established during coining, to form an unmelted bond of diffused metal between the fibers at points of contact and more firmly attach the bus connectors and provide an unoxidized bonded, laminated electrode plaque of bonded metal fibers free of melt protuberances suitable for coating, and then F. coating the bonded, laminated plaque with a metal coating selected from the group consisting of nickel, cadmium, copper, and silver, having a thickness from about 0.1 to 1 mil.
Claim 9
Dependent Claim
42 words
The method of claim 9 wherein each layer has its fibers oriented between 30* and 90* from the fibers of adjacent layers, the bus connector portion is up to about 50 percent porous and a nickel tab is attached to the plaque.
References Cited (Backward Citations)
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1977-09-16 | 1978-03-18 | 1978-09-17 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1981-09-16 | 1982-03-18 | 1982-09-17 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1985-09-16 | 1986-03-18 | 1986-09-17 | $7700.00 | Window Closed / Lapsed |