Method of making a flat battery

Claim 1

A method for constructing flat battery units comprising the steps of: providing first current collectors, each having a lengthwise and widthwise dimension; providing a continuous carrier sheet of electrically insulative material having a widthwise dimension at least as great as the widthwise dimension of said first current collectors; intermittently depositing in predetermined spaced sequential alignment upon one side of said continuous carrier sheet said first current collectors; thereon depositing in a predetermined sequence superposed on each first current collector electrolyte, anode materials, cathode materials, separators and intercell connectors; and thereon depositing a second current collector to form discrete electrically coupled flat cell assemblies; and cutting said continuous carrier sheet between said discrete cell assemblies to provide discrete battery units comprising a sheet of electrically insulative material at least coextensive in size with a first current collector.

Claim 2

A method for constructing flat battery units comprising the steps of: providing first current collectors, each having a lengthwise and widthwise dimension; providing a continuous carrier sheet of electrically insulative material having a widthwise dimension at least as great as the widthwise dimension of said first current collectors; intermittently depositing in predetermined spaced sequential alignment upon one side of said continuous carrier sheet said first current collectors; thereon depositing in a predetermined sequence superposed on each first current collector electrolyte, anode materials, cathode materials, separators and intercell connectors; and thereon depositing a second current collector to form discrete electrically coupled flat cell assemblies; and cutting said continuous carrier sheet between said discrete cell assemblies to provide discrete battery units comprising a sheet of electrically insulative material at least coextensive in size with a first current collector.

Claim 9

A method for constructing flat multicell batteries comprising the steps of: providing a continuous carrier sheet of electrically insulative material having intermittently spaced access openings; intermittently fixedly positioning discrete first current collectors in predetermined spaced sequential relationship directly upon one side of said continuous carrier sheet, each of said first current collectors being spaced coincidentally with one of said intermittent access openings in said insulative carrier sheet thereby forming a first battery terminal; forming a predetermined number of cells upon each said collector, said cells including intercell connectors, and cathode and anode electrodes between which is disposed electrolyte and separator means; positioning discrete second collector assemblies over and in electrochemical association with the uppermost of said cells to form a multicell unit, said second collector assemblies having a width selectively extending beyond the edge of said continuous carrier sheet; folding said width of said second collector assembly extending beyond said carrier sheet about the edge thereof to a position juxtaposed against a surface thereof, thereby forming a second battery terminal on the same side of said battery as said first terminal; and sealing the periphery of each said multicell unit.

Claim 10

A method for constructing flat multicell batteries comprising the steps of: providing a continuous carrier sheet of electrically insulative material having intermittently spaced access openings; intermittently fixedly positioning discrete first current collectors in predetermined spaced sequential relationship directly upon one side of said continuous carrier sheet, each of said first current collectors being spaced coincidentally with one of said intermittent access openings in said insulative carrier sheet thereby forming a first battery terminal; forming a predetermined number of cells upon each said collector, said cells including intercell connectors, and cathode and anode electrodes between which is disposed electrolyte and separator means; positioning discrete second collector assemblies over and in electrochemical association with the uppermost of said cells to form a multicell unit, said second collector assemblies having a width selectively extending beyond the edge of said continuous carrier sheet; folding said width of said second collector assembly extending beyond said carrier sheet about the edge thereof to a position juxtaposed against a surface thereof, thereby forming a second battery terminal on the same side of said battery as said first terminal; and sealing the periphery of each said multicell unit.

Claim 15

A method for making flat multicell primary batteries comprising the steps of: providing a discrete laminar first current collector assembly having a lengthwise and widthwise dimension; providing a continuous carrier sheet of electrically insulative material having a widthwise dimension at least as great as the widthwise dimension of said discrete laminar first current collector; intermittently positioning a discrete laminar first current collector assembly upon said carrier sheet, said assembly having a metallic surface positional against said carrier sheet and an oppositely disposed electrically conductive material supporting a first electrode; positioning electrolyte, discrete separator and discrete intercell connectors carrying complementing electrode materials over said first current collector assembly to provide a multicell subassembly; selectively intersealing said carrier sheet, said first current collector assembly, said discrete separator and said intercell connector; positioning a discrete laminar second current assembly upon each said multicell subassembly, said second collector assembly having an electrode supporting electrically conducting material positioned in operative relationship with said multicell assembly and an outwardly facing metallic surface; and sealing the periphery of said multicell subassembly and said second collector assembly.

Claim 16

A method for making flat multicell primary batteries comprising the steps of: providing a discrete laminar first current collector assembly having a lengthwise and widthwise dimension; providing a continuous carrier sheet of electrically insulative material having a widthwise dimension at least as great as the widthwise dimension of said discrete laminar first current collector; intermittently positioning a discrete laminar first current collector assembly upon said carrier sheet, said assembly having a metallic surface positional against said carrier sheet and an oppositely disposed electrically conductive material supporting a first electrode; positioning electrolyte, discrete separator and discrete intercell connectors carrying complementing electrode materials over said first current collector assembly to provide a multicell subassembly; selectively intersealing said carrier sheet, said first current collector assembly, said discrete separator and said intercell connector; positioning a discrete laminar second current assembly upon each said multicell subassembly, said second collector assembly having an electrode supporting electrically conducting material positioned in operative relationship with said multicell assembly and an outwardly facing metallic surface; and sealing the periphery of said multicell subassembly and said second collector assembly.