US5480462A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Method of forming button-type battery lithium electrodes
Assignee: Round Rock Research LLC
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Filing: 1994-07-06
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Granted: 1996-01-02
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Expires: 2014-07-06
Abstract
Abstract A method of forming a button-type lithium electrode includes: a) masking an electrically conductive sheet with a material to which elemental lithium will not appreciably adhere to define a masked portion and an unmasked portion, the unmasked portion being in the shape of the desired electrode being formed; c) applying molten lithium to the masked sheet to cause elemental lithium to adhere to the unmasked portion but not appreciably adhere to the masked portion; alternately, directing a lithium stream onto the sheet; d) solidifying the lithium on the unmasked portion to in situ form a lithium electrode; and e) after solidifying, removing the masking material from the masked portion of the sheet. An alternate method includes: a) providing a release liner sheet having elemental lithium adhered thereto in the form of a series of discrete patterns having a size and shape of the lithium electrodes being formed; b) providing an electrically conductive sheet having an exposed surface which is divisible into a plurality of areas; c) laminating the release liner sheet with the conductive sheet to adhere the series of discrete elemental lithium patterns onto the respective sheet areas; d) pulling the release liner sheet from the conductive sheet and discrete lithium patterns, leaving the discrete lithium patterns adhering to the conductive sheet; and e) cutting and forming a plurality of discrete battery terminal housing members from the areas of the sheet, with each of the discrete battery terminal housings bearing one of the discrete lithium patterns.
Inventors
- 👤 Mark E. Tuttle
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-09 16:17
CPC Classifications
H; H01; H01M; H01M4/00; H01M4/02; H01M4/04; H01M4/0402; H01M4/0421; H01M4/043; H01M4/0435; H01M4/0483; H01M50/00; H01M50/10; H01M50/102; H01M50/109; H01M50/147; H01M6/00; H01M6/14; H01M6/16; H01M6/40; Y; Y10; Y10T; Y10T29/00; Y10T29/49; Y10T29/49002; Y10T29/49108; Y10T29/49112; Y10T29/49115
Claims Analysis
Total Claims: 22
Claim 1
Independent Claim
142 words
A method of forming a button-type lithium electrode comprising the following steps: providing an electrically conductive sheet having an exposed surface, the electrically conductive sheet being comprised of a material to which elemental lithium will adhere; masking the electrically conductive sheet with a material to which elemental lithium will not appreciably adhere, the masking defining a masked portion and an unmasked portion, the unmasked portion of the conductive sheet having a cross-sectional size and shape of the desired electrode being formed; applying molten lithium to the masked electrically conductive sheet to cause elemental lithium to adhere to the unmasked portion but not appreciably adhere to the masked portion; solidifying the elemental lithium on the unmasked portion to in situ form a lithium electrode on the unmasked portion; and after solidifying, removing the masking material from the masked portion of the conductive sheet.
Claim 2
Independent Claim
142 words
A method of forming a button-type lithium electrode comprising the following steps: providing an electrically conductive sheet having an exposed surface, the electrically conductive sheet being comprised of a material to which elemental lithium will adhere; masking the electrically conductive sheet with a material to which elemental lithium will not appreciably adhere, the masking defining a masked portion and an unmasked portion, the unmasked portion of the conductive sheet having a cross-sectional size and shape of the desired electrode being formed; applying molten lithium to the masked electrically conductive sheet to cause elemental lithium to adhere to the unmasked portion but not appreciably adhere to the masked portion; solidifying the elemental lithium on the unmasked portion to in situ form a lithium electrode on the unmasked portion; and after solidifying, removing the masking material from the masked portion of the conductive sheet.
Claim 3
Dependent Claim
89 words
The method of forming a button-type lithium electrode of claim 1 wherein the electrically conductive sheet is provided in the form of a pre-formed electrically conductive terminal housing member prior to the masking and applying steps, the preformed terminal housing member defining an electrode receptacle having a peripheral portion and a central portion, the peripheral portion angling away from the central portion at a peripheral angle to define a central portion cross-sectional shape and periphery, the masked portion comprising the peripheral portion, the unmasked portion comprising the central portion.
Claim 4
Dependent Claim
97 words
The method of forming a button-type lithium electrode of claim 1 wherein the electrically conductive sheet is provided in the form of a pre-formed electrically conductive terminal housing member prior to the masking and applying steps, the preformed terminal housing member defining an electrode receptacle having an internal peripheral portion and a central portion, the peripheral portion angling away from the central portion at a peripheral angle to define a central portion cross-sectional shape and periphery, the masked portion covering all of the internal peripheral portion, the unmasked portion at least exposing all of the central portion.
Claim 5
Dependent Claim
54 words
The method of forming a button-type lithium electrode of claim 1 wherein the electrically conductive sheet is not pre-formed into a terminal housing member shape prior to the masking and applying steps, the method further comprising after the solidifying step: cutting and forming a discrete battery terminal housing member from the electrically conductive sheet.
Claim 6
Dependent Claim
32 words
The method of forming a button-type lithium electrode of claim 1 wherein the electrically conductive sheet is at a temperature below the melting point of lithium immediately prior to the applying step.
Claim 7
Dependent Claim
111 words
The method of forming a button-type lithium electrode of claim 1 wherein the electrically conductive sheet is provided in the form of a pre-formed electrically conductive terminal housing member prior to the masking and applying steps, the preformed terminal housing member defining an electrode receptacle having a peripheral portion and a central portion, the peripheral portion angling away from the central portion at a peripheral angle to define a central portion cross-sectional shape and periphery, the masked portion comprising the peripheral portion, the unmasked portion comprising the central portion; and wherein the electrically conductive sheet is at a temperature below the melting point of lithium immediately prior to the applying step.
Claim 8
Dependent Claim
119 words
The method of forming a button-type lithium electrode of claim 1 wherein the electrically conductive sheet is provided in the form of a pre-formed electrically conductive terminal housing member prior to the masking and applying steps, the preformed terminal housing member defining an electrode receptacle having an internal peripheral portion and a central portion, the peripheral portion angling away from the central portion at a peripheral angle to define a central portion cross-sectional shape and periphery, the masked portion covering all of the internal peripheral portion, the unmasked portion at least exposing all of the central portion; and wherein the electrically conductive sheet is at a temperature below the melting point of lithium immediately prior to the applying step.
Claim 9
Dependent Claim
76 words
The method of forming a button-type lithium electrode of claim 1 wherein the electrically conductive sheet is not pre-formed into a terminal housing member shape prior to the masking and applying steps; wherein the electrically conductive sheet is at a temperature below the melting point of lithium immediately prior to the applying step, and the method further comprising after the solidifying step: cutting and forming a discrete battery terminal housing member from the electrically conductive sheet.
Claim 10
Independent Claim
126 words
A method of forming a button-type lithium electrode comprising the following steps: providing an electrically conductive sheet having an exposed surface, the electrically conductive sheet being comprised of a material to which elemental lithium will adhere; masking the electrically conductive sheet with a material to which elemental lithium will not appreciably adhere, the masking defining a masked portion and an unmasked portion, the unmasked portion of the conductive sheet having a cross-sectional size and shape of the desired electrode being formed; providing and directing a lithium stream onto the electrically conductive sheet to cause elemental lithium to adhere to the unmasked portion but not appreciably adhere to the masked portion; and solidifying the lithium stream on the unmasked portion to in situ form a lithium electrode.
Claim 11
Independent Claim
126 words
A method of forming a button-type lithium electrode comprising the following steps: providing an electrically conductive sheet having an exposed surface, the electrically conductive sheet being comprised of a material to which elemental lithium will adhere; masking the electrically conductive sheet with a material to which elemental lithium will not appreciably adhere, the masking defining a masked portion and an unmasked portion, the unmasked portion of the conductive sheet having a cross-sectional size and shape of the desired electrode being formed; providing and directing a lithium stream onto the electrically conductive sheet to cause elemental lithium to adhere to the unmasked portion but not appreciably adhere to the masked portion; and solidifying the lithium stream on the unmasked portion to in situ form a lithium electrode.
Claim 12
Dependent Claim
89 words
The method of forming a button-type lithium electrode of claim 9 wherein the electrically conductive sheet is provided in the form of a pre-formed electrically conductive terminal housing member prior to the directing and solidifying steps, the preformed terminal housing member defining an electrode receptacle having a peripheral portion and a central portion, the peripheral portion angling away from the central portion at a peripheral angle to define a central portion cross-sectional shape and periphery, the masked portion comprising the peripheral portion, the unmasked portion comprising the central portion.
Claim 13
Dependent Claim
97 words
The method of forming a button-type lithium electrode of claim 9 wherein the electrically conductive sheet is provided in the form of a pre-formed electrically conductive terminal housing member prior to the directing and solidifying steps, the preformed terminal housing member defining an electrode receptacle having an internal peripheral portion and a central portion, the peripheral portion angling away from the central portion at a peripheral angle to define a central portion cross-sectional shape and periphery, the masked portion covering all of the internal peripheral portion, the unmasked portion at least exposing all of the central portion.
Claim 14
Dependent Claim
53 words
The method of forming a button-type lithium electrode of claim 9 wherein the electrically conductive sheet is not pre-formed into a terminal housing member shape prior to directing and solidifying steps, the method further comprising after the solidifying step: cutting and forming a discrete battery terminal housing member from the electrically conductive sheet.
Claim 15
Dependent Claim
27 words
The method of forming a button-type battery lithium electrode of claim 9 wherein the lithium stream is provided and directed in the form of a liquid stream.
Claim 16
Dependent Claim
89 words
The method of forming a button-type lithium electrode of claim 13 wherein the electrically conductive sheet is provided in the form of a pre-formed electrically conductive terminal housing member prior to the directing and solidifying steps, the preformed terminal housing member defining an electrode receptacle having a peripheral portion and a central portion, the peripheral portion angling away from the central portion at a peripheral angle to define a central portion cross-sectional shape and periphery, the masked portion comprising the peripheral portion, the unmasked portion comprising the central portion.
Claim 17
Dependent Claim
97 words
The method of forming a button-type lithium electrode of claim 13 wherein the electrically conductive sheet is provided in the form of a pre-formed electrically conductive terminal housing member prior to the directing and solidifying steps, the preformed terminal housing member defining an electrode receptacle having an internal peripheral portion and a central portion, the peripheral portion angling away from the central portion at a peripheral angle to define a central portion cross-sectional shape and periphery, the masked portion covering all of the internal peripheral portion, the unmasked portion at least exposing all of the central portion.
Claim 18
Dependent Claim
53 words
The method of forming a button-type lithium electrode of claim 13 wherein the electrically conductive sheet is not pre-formed into a terminal housing member shape prior to directing and solidifying steps, the method further comprising after the solidifying step: cutting and forming a discrete battery terminal housing member from the electrically conductive sheet.
Claim 19
Dependent Claim
27 words
The method of forming a button-type battery lithium electrode of claim 9 wherein the lithium stream is provided and directed in the form of a vaporized stream.
Claim 20
Dependent Claim
89 words
The method of forming a button-type lithium electrode of claim 17 wherein the electrically conductive sheet is provided in the form of a pre-formed electrically conductive terminal housing member prior to the directing and solidifying steps, the preformed terminal housing member defining an electrode receptacle having a peripheral portion and a central portion, the peripheral portion angling away from the central portion at a peripheral angle to define a central portion cross-sectional shape and periphery, the masked portion comprising the peripheral portion, the unmasked portion comprising the central portion.
Claim 21
Dependent Claim
97 words
The method of forming a button-type lithium electrode of claim 17 wherein the electrically conductive sheet is provided in the form of a pre-formed electrically conductive terminal housing member prior to the directing and solidifying steps, the preformed terminal housing member defining an electrode receptacle having an internal peripheral portion and a central portion, the peripheral portion angling away from the central portion at a peripheral angle to define a central portion cross-sectional shape and periphery, the masked portion covering all of the internal peripheral portion, the unmasked portion at least exposing all of the central portion.
Claim 22
Dependent Claim
53 words
The method of forming a button-type lithium electrode of claim 17 wherein the electrically conductive sheet is not pre-formed into a terminal housing member shape prior to directing and solidifying steps, the method further comprising after the solidifying step: cutting and forming a discrete battery terminal housing member from the electrically conductive sheet.
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) | 1999-01-01 | 1999-07-03 | 2000-01-02 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2003-01-01 | 2003-07-03 | 2004-01-02 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2007-01-01 | 2007-07-03 | 2008-01-02 | $7700.00 | Window Closed / Lapsed |