US4790969A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Dry molded cathode collector for liquid cathode systems
Assignee: Edgewell Personal Care Brands LLC
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Filing: 1987-07-16
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Granted: 1988-12-13
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Expires: 2007-07-16
Abstract
Abstract Disclosed is a method of forming porous carbon cathode collectors for electrochemical cells by mixing carbon black with binder and liquid to form a dough, drying it at an elevated temperature, compacting the dried mix at an elevated temperature, milling it to a particle size greater than 0.05 mm and preferably 0.1 to 0.3 mm, and molding the dry milled mix, preferably by auger feeding, to form a collector having a pore size at least 50% by volume being 10 microns or larger and most preferably in the range of 10 to 90 microns.
Inventors
- 👤 John C. Bailey
- 👤 Timothy D. Foley
- 👤 Ernest D. Botos
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-09 18:15
CPC Classifications
H; H01; H01M; H01M6/00; H01M6/14; H01M4/00; H01M4/86; H01M4/96; Y; Y02; Y02E; Y02E60/00; Y02E60/30; Y02E60/50
Claims Analysis
Total Claims: 12
Claim 1
Independent Claim
126 words
A method of forming porous carbon cathode collectors for electrochemical cells comprising the steps of: mixing carbon black and binder with sufficient added liquid to obtain effective distribution of the binder with the carbon black in the form of a dough; drying the dough mix to remove the added liquid; compacting by rolling to improve the cohesive nature of the dry mix while at an elevated temperature less than about 300 degrees C.; milling the dry compacted mix of carbon black and binder only until substantially all of the particles are greater than about 0.05 mm in diameter; and press molding the dry milled mix into a resultant porous collector with at least 50% by volume of the pores being 10 microns or larger in size.
Claim 2
Independent Claim
126 words
A method of forming porous carbon cathode collectors for electrochemical cells comprising the steps of: mixing carbon black and binder with sufficient added liquid to obtain effective distribution of the binder with the carbon black in the form of a dough; drying the dough mix to remove the added liquid; compacting by rolling to improve the cohesive nature of the dry mix while at an elevated temperature less than about 300 degrees C.; milling the dry compacted mix of carbon black and binder only until substantially all of the particles are greater than about 0.05 mm in diameter; and press molding the dry milled mix into a resultant porous collector with at least 50% by volume of the pores being 10 microns or larger in size.
Claim 3
Dependent Claim
35 words
The method in claim 1 wherein said drying step includes elevating the temperature of said mix to less than about 300 degrees C., and said compacting step is performed while the temperature is still elevated.
Claim 4
Dependent Claim
29 words
The method of claim 1 wherein said step of milling is conducted until the particles are substantially in the range of about 0.1 to about 0.3 mm in diameter.
Claim 5
Dependent Claim
31 words
The method in claim 1 wherein said press molding step is performed until at least about 39% by volume of the pores constitutes pores about 26 microns or larger in diameter.
Claim 6
Dependent Claim
36 words
The method in claim 1 wherein said press molding step is performed until at least about 40% by volume of the pores constitutes pores in the range of about 10 to about 100 microns in diameter.
Claim 7
Dependent Claim
36 words
The method in claim 1 wherein said press molding step is performed until at least about 50% by volume of the pores constitutes pores in the range of about 10 to about 90 microns in diameter.
Claim 8
Dependent Claim
40 words
The method in claim 1 wherein said press molding step is performed by auger feeding said milled mix into a cylindrical mold cavity between an outside mold and an inside core and pressing the molded mix with further auger feeding.
Claim 9
Dependent Claim
21 words
The method in claim 1 wherein said collector is molded to a final porosity of about 80 to 90% by volume.
Claim 10
Independent Claim
160 words
A method of forming porous carbon cathode collectors for electrochemical cells comprising the steps of: mixing carbon black and binder with sufficient added liquid to obtain effective distribution of the binder with the carbon black in the form of a dough; drying the dough mix to remove the added liquid at an elevated temperature less than about 300 degrees C.; compacting by rolling to improve the cohesive nature of the dry mix while still at an elevated temperature less than about 300 degrees C.; milling the dry compacted mix of carbon black and binder only until the particles are substantially in the range of about 0.1 to about 0.3 mm; and press molding by auger feeding the dry milled mix to form a resultant porous collector with at least 40% by volume of the pores being in the range of about 10 microns to about 100 microns in diameter, and having a porosity of about 80% to 90% by volume.
Claim 11
Independent Claim
160 words
A method of forming porous carbon cathode collectors for electrochemical cells comprising the steps of: mixing carbon black and binder with sufficient added liquid to obtain effective distribution of the binder with the carbon black in the form of a dough; drying the dough mix to remove the added liquid at an elevated temperature less than about 300 degrees C.; compacting by rolling to improve the cohesive nature of the dry mix while still at an elevated temperature less than about 300 degrees C.; milling the dry compacted mix of carbon black and binder only until the particles are substantially in the range of about 0.1 to about 0.3 mm; and press molding by auger feeding the dry milled mix to form a resultant porous collector with at least 40% by volume of the pores being in the range of about 10 microns to about 100 microns in diameter, and having a porosity of about 80% to 90% by volume.
Claim 12
Dependent Claim
36 words
The method in claim 9 wherein said press molding step is performed until at least about 50% by volume of the pores constitutes pores in the range of about 10 to about 90 microns in diameter.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1991-12-13 | 1992-06-13 | 1992-12-13 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1995-12-13 | 1996-06-13 | 1996-12-13 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1999-12-13 | 2000-06-13 | 2000-12-13 | $7700.00 | Window Closed / Lapsed |