A method for manufacturing an alkaline zinc-manganese battery and its separator cartridge.

Abstract

This invention discloses an alkaline zinc-manganese battery and a method for manufacturing the separator of the alkaline zinc-manganese battery, relating to the field of chemical power sources. The battery includes: a shell, multiple positive electrode rings, a spiral cylindrical separator, a current collector, zinc paste electrolyte, and a filling ring. The upper end of the filling ring abuts against the sealing ring. The spiral cylindrical separator is formed by winding parallelogram-shaped separator paper. The outermost separator paper has a spirally closed sealing edge with an inclined angle, allowing it to adhere tightly to the inner separator paper, preventing opening and enhancing its resistance to deformation. The sealing ring completely contracts the opening of the separator, improving the battery's vibration resistance. The filling ring is positioned in the space lacking the positive electrode ring, effectively preventing zinc paste overflowing from the negative electrode from contacting the positive electrode, avoiding the risk of internal short circuits leading to battery overheating, leakage, or even failure. The filling ring provides axial support to the positive electrode ring, preventing the manganese ring from floating when the battery is impacted, thus maintaining the stability of the battery's internal structure.

Description

Technical Field

[0001] This invention relates to the field of chemical power source technology, and in particular to an alkaline zinc-manganese battery and a method for manufacturing the separator of the alkaline zinc-manganese battery. Background Technology

[0002] Alkaline zinc-manganese batteries have advantages such as high energy efficiency, long storage time, moderate cost, reliable safety performance, and wide applicability. Currently, the majority of zinc-manganese batteries are still inexpensive zinc-manganese dry cell batteries, resulting in low adoption rates for alkaline zinc-manganese batteries. Low-cost alkaline zinc-manganese batteries are not only more affordable for local consumer levels, but also free of heavy metals such as mercury, making them more environmentally friendly and enabling them to achieve stronger market penetration and competitiveness.

[0003] Currently, to reduce the cost of alkaline zinc-manganese batteries, the amount of active material in the positive or negative electrode is reduced, and the height of the positive and negative electrodes is lowered. This results in the lack of axial support on the inner and outer sides of the separator tube at the opening of the steel casing. When the battery is subjected to external impact, the separator tube is easily deformed, and the manganese ring is prone to floating. Furthermore, the sealing edge of the outermost separator paper in ordinary separator tubes is prone to folding outward, resulting in an extended seal. The seal cannot fully retract into the annular truncated pyramid of the sealing ring. When the battery vibrates or is dropped, the zinc paste inside the separator tube can easily overflow to the positive electrode, causing the battery to short-circuit and fail. In addition, after the open separator paper is rolled outward, it can easily overlap with the adhesive layer of the steel casing. Alkali solution can cross the adhesive layer, causing the battery to leak alkali, creating a safety hazard and resulting in low safety and reliability.

[0004] Although existing technologies disclose methods to reduce the deformation of the diaphragm tube by adding support members, for example, patent document with application number 202211644266.0 discloses an economical alkaline zinc-manganese cylindrical battery, which uses a support member near the positive terminal of the battery to support the bottom of the diaphragm tube, so that the top of the diaphragm tube is pressed against the current collector, preventing leakage due to deformation; however, the top opening of the diaphragm tube in this method still has the problem of being rolled out and not fully retracted into the sealing ring or not pressing against the sealing ring. In addition, the two layers of the diaphragm tube are relatively thin, making it very easy to bend or collapse. When the battery is impacted, there is still a risk that the zinc paste and electrolyte inside the diaphragm tube will leak out from the opening of the diaphragm tube. Summary of the Invention

[0005] The purpose of this invention is to address the problem in existing economical alkaline zinc-manganese batteries that, due to the reduction of positive and negative electrode filling materials, easily lead to deformation of the separator or extension of the top seal, resulting in leakage or short circuits. This invention provides an alkaline zinc-manganese battery and a method for manufacturing the separator of the alkaline zinc-manganese battery.

[0006] To achieve the above objectives, the technical solution adopted by the present invention is as follows:

[0007] An alkaline zinc-manganese battery includes: a casing, multiple positive electrode rings, a spiral cylindrical separator, a current collector, and zinc paste electrolyte; the multiple positive electrode rings are axially stacked inside the casing, and the spiral cylindrical separator is placed inside the multiple positive electrode rings; the bottom of the spiral cylindrical separator abuts against the positive terminal; the top seal of the spiral cylindrical separator is inwardly contracted and abuts against the sealing ring of the current collector; the spiral cylindrical separator includes three layers of separator paper formed by winding a single separator paper, the innermost and outermost sealing edges of the separator paper being axially spiraled and overlapping; the outermost sealing edge of the separator paper is away from both ends of the spiral cylindrical separator; the zinc paste electrolyte is filled inside the spiral cylindrical separator.

[0008] The alkaline zinc-manganese battery of this invention has a bottom section of a spiral cylindrical separator abutting against the positive terminal, and a top seal that contracts and abuts against the sealing ring of the current collector. During vibration or external impact, the top seal, through the spiral cylindrical separator, enhances the sidewall support strength of the separator by causing the innermost and outermost layers of the three-layer separator paper to spiral and overlap axially. This reduces the probability of the separator being flattened or deformed during vibration or impact, making it less prone to opening and increasing its resistance to deformation. This design enhances the safety and reliability of alkaline zinc-manganese batteries, thereby reducing the risk of leakage or short circuits. Furthermore, by utilizing the sealing principle of the outermost separator paper at both ends of the spiral cylindrical separator tube, after the separator tube is installed in the outer casing, the sealing edge is not close to the top or bottom of the spiral cylindrical separator tube, preventing the sealing edge from rolling out. This allows the seal at the top of the separator tube to fully contract and abut against the sealing ring of the current collector, avoiding leakage or short circuits caused by an opening at the top of the separator tube. These two aspects combined improve the safety and reliability of alkaline zinc-manganese batteries.

[0009] Preferably, in the alkaline zinc-manganese battery of the present invention, the sealing ring has an axially recessed abutment groove on the side near the spiral cylindrical diaphragm cylinder; the side wall of the abutment groove abuts radially against the outer side wall of the spiral cylindrical diaphragm cylinder; and the top wall of the abutment groove abuts against the top seal of the spiral cylindrical diaphragm cylinder.

[0010] As a preferred embodiment of the present invention, by setting an abutment groove in the sealing ring, the sidewall of the abutment groove abuts radially against the outer sidewall of the spiral cylindrical diaphragm tube, thereby enhancing the lateral protective force on the top seal of the spiral cylindrical diaphragm tube and reducing the possibility of deformation or outward turning of the top seal. Correspondingly, the top wall of the abutment groove abuts against the top seal of the spiral cylindrical diaphragm tube, thereby enhancing the axial protection of the top seal. This further enhances the protective effect on the top seal of the spiral cylindrical diaphragm tube in both the axial and radial directions, further reducing the risk of zinc paste electrolyte leaking from the top seal of the spiral cylindrical diaphragm tube and improving the reliability of the alkaline zinc-manganese battery.

[0011] Preferably, the alkaline zinc-manganese battery of the present invention further includes a filling ring; a plurality of positive electrode rings are stacked axially along the positive electrode to the negative electrode of the battery; the filling ring is disposed above the positive electrode ring near the negative electrode of the battery; the inner side of the filling ring is hollow, so that the spiral cylindrical separator can pass through; the upper end of the filling ring abuts against the sealing ring; the height of the filled zinc paste electrolyte is equal to the height of the positive electrode ring.

[0012] As a preferred embodiment of the present invention, by setting positive electrode rings stacked axially from the positive electrode to the negative electrode of the battery, and setting a filling ring above the positive electrode ring near the negative electrode of the battery, the filling height of the zinc paste electrolyte is equal to the stacking height of the positive electrode ring. On the one hand, there is no sinking section of the negative electrode active material, and all the filled zinc paste electrolyte can be utilized, enhancing the utilization rate of the zinc paste electrolyte. On the other hand, the section of the spiral cylindrical separator corresponding to the filling ring does not need to be filled with zinc paste electrolyte, and does not affect the stability of the battery function, saving the amount of filler, reducing costs, and improving the economic benefits of the alkaline zinc-manganese battery. In conjunction with this, by setting the filling ring, when the battery is dropped or deformed by vibration, it can be supported on the side of the spiral cylindrical separator near the top seal, directly reducing the risk of the spiral cylindrical separator being flattened or radially squeezed and deformed, and effectively preventing the zinc paste overflowing from the negative electrode from contacting the positive electrode, thereby avoiding the risk of internal short circuits in the battery leading to overheating, leakage, and failure, further improving the safety and reliability of the alkaline zinc-manganese battery.

[0013] Preferably, in the alkaline zinc-manganese battery of the present invention, the relationship between the height H1 of the filling ring and the total height H of the battery is: 0.04H≤H1≤0.5H.

[0014] As a preferred embodiment of the present invention, by setting the ratio of the height of the filling ring to the total height of the battery, the amount of filler without zinc electrolyte can be controlled as much as possible while the battery can stably generate electrical energy, thereby reducing costs and improving economic efficiency.

[0015] Preferably, in the alkaline zinc-manganese battery of the present invention, the filling ring is composed of at least one of polyimide solid foam, polyetheretherketone, nylon, polytetrafluoroethylene, and silicone resin.

[0016] As a preferred embodiment of the present invention, by setting the filling ring as at least one of the polyimide solid foam, polyetheretherketone, nylon, polytetrafluoroethylene, and silicone resin, the filling ring has a certain elastic deformation capability, enhances the resistance to compression or deformation, and can reduce the weight of the battery, reduce the cost of the filling ring, and improve the economic benefits of the battery.

[0017] Preferably, in the alkaline zinc-manganese battery of the present invention, the outer wall of the filling ring is provided with an arc-shaped groove that is concave in the radial direction.

[0018] As a preferred embodiment of the present invention, by setting the outer side wall of the filling ring to a radially concave arc-shaped groove, an axial bow-shaped support can be formed, enhancing the axial support strength and having a certain axial elastic deformation capability, avoiding the upper and lower sides of the filling ring from being squeezed and broken, enhancing the protective performance of the filling ring, further reducing the risk of leakage due to damage to the filling ring, and improving the leakage prevention performance.

[0019] Preferably, in the alkaline zinc-manganese battery of the present invention, the height of the filling ring is H1, and the relationship between the heights H2 and H1 of the arc-shaped groove is: H2 = 0.8H1.

[0020] As a preferred embodiment of the present invention, by setting the ratio between the height of the arc-shaped groove and the height of the filling ring, the elastic deformation capability of the arc-shaped groove can be further enhanced, and the compression resistance and deformation resistance of the filling ring can be improved.

[0021] To achieve the objective of this invention, a method for manufacturing a separator for an alkaline zinc-manganese battery is provided, comprising the following steps:

[0022] S1. Adjust the angle of the cutter and cut the diaphragm paper into a parallelogram with an acute angle of α, a base length of L, and a height of H3.

[0023] S2. The acute angle end of the diaphragm paper is fed into the winding rod, and the winding rod is rotated to wind the diaphragm paper into a spiral cylindrical diaphragm tube, so that the diaphragm paper is a three-layer diaphragm paper, the innermost sealing edge and the outermost sealing edge are spirally intersected and overlapped axially, and the outermost sealing edge is away from both ends of the spiral cylindrical diaphragm tube.

[0024] S3. The bottom of the semi-finished product made in S2 is sealed by a hot-seal process to form a spiral cylindrical diaphragm tube.

[0025] The method for manufacturing the separator tube of the alkaline zinc-manganese battery according to the present invention, wherein the spiral is understood as the process of cutting and winding in steps S1 to S2 to achieve the spiral rotation and winding of the side of the parallelogram-shaped separator paper to form a spiral cylindrical separator tube. The resulting separator tube has strong axial support strength and stronger resistance to deformation because the innermost and outermost layers of the three-layer separator paper are spirally and cross-overlapping. The sealing edge of the resulting spiral cylindrical separator tube is far away from both ends, making it difficult for the sealing edge to turn outward or open, especially the top seal, which is not easy to open. This avoids the top separator paper from overlapping with the steel shell coating layer, thereby preventing the alkaline solution from crossing the coating layer and causing the battery to leak alkaline solution, thus improving the reliability and safety of the battery.

[0026] Preferably, in the method for manufacturing the separator tube of the alkaline zinc-manganese battery of the present invention, the acute angle α is selected in the range of 50° to 80°; the paper feeding direction at one end of the acute angle is perpendicular to the winding direction.

[0027] As a preferred embodiment of the present invention, the acute angle α is set to a range of 50° to 80°, and one side of the parallelogram-shaped diaphragm paper is used as the sealing edge, so that the length of the sealing edge matches the circumference of the diaphragm tube, and the paper feeding direction at the acute angle end is perpendicular to the winding direction, so that the sealing edges of the innermost and outermost diaphragm papers can overlap as much as possible, further improving the deformation resistance of the diaphragm tube.

[0028] In summary, due to the adoption of the above technical solution, the beneficial effects of the present invention are:

[0029] 1. The spiral cylindrical diaphragm tube has stronger resistance to deformation. The innermost and outermost layers of the three-layer diaphragm paper are axially spiral and cross-over, which can enhance the side wall support strength of the diaphragm tube. In this way, when subjected to external vibration or impact, the probability of the diaphragm tube being flattened or deformed is reduced. It is not easy to open, has stronger resistance to deformation, and reduces the risk of leakage or short circuit.

[0030] 2. By combining the sealing principle of the outermost separator paper at both ends of the spiral cylindrical separator tube, after the separator tube is installed in the outer shell, the sealing edge is not close to the top or bottom of the spiral cylindrical separator tube, which can prevent the sealing edge from rolling out. This allows the seal at the top of the separator tube to completely shrink and abut against the sealing ring of the current collector, avoiding leakage or short circuit caused by the opening at the top of the separator tube. The combination of the above two aspects improves the safety and reliability of alkaline zinc-manganese batteries. Attached Figure Description

[0031] Figure 1 This is a schematic diagram of the structure of the alkaline zinc-manganese battery of the present invention;

[0032] Figure 2 This is a schematic diagram of the structure of the spiral cylindrical diaphragm tube of the present invention;

[0033] Figure 3 This is a schematic diagram of the axial cross-section of the filling ring of the present invention;

[0034] Figure 4 This is a top view of the filling ring of the present invention;

[0035] Figure 5 This is a three-dimensional structural schematic diagram of the filling ring of the present invention;

[0036] Figure 6 This is an X-ray transmission view of the alkaline zinc-manganese battery described in Embodiment 1 of the present invention;

[0037] Figure 7 This is an X-ray transmission view of the alkaline zinc-manganese battery described in Comparative Example 1 of the present invention;

[0038] Figure 8This is an X-ray projection view of the alkaline zinc-manganese battery described in Comparative Example 2 of the present invention after it has been dropped.

[0039] Figure 9 This is an X-ray projection view of the alkaline zinc-manganese battery described in Embodiment 2 of the present invention after it has been dropped;

[0040] Figure 10 This is a schematic diagram of the state of a conventional separator tube for the alkaline zinc-manganese battery described in Comparative Example 1 of the present invention;

[0041] Figure 11 This is a schematic diagram simulating the cutting and winding of the diaphragm paper according to the present invention.

[0042] 1. Outer shell; 2. Positive electrode ring; 3. Spiral cylindrical diaphragm tube; 31. Diaphragm paper; 311. Innermost sealing edge; 312. Outermost sealing edge; 4. Current collector; 41. Sealing ring; 411. Abutment groove; 42. Current collector needle; 43. Negative terminal; 5. Zinc paste electrolyte; 6. Positive terminal; 7. Filler ring; 71. Arc-shaped groove; 8. Winding rod; 100. Ordinary diaphragm tube; 101. Ordinary sealing edge. Detailed Implementation

[0043] The present invention will now be described in detail with reference to the accompanying drawings.

[0044] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention.

[0045] Example 1:

[0046] like Figure 1 As shown, this embodiment provides an alkaline zinc-manganese battery, including: a shell 1, multiple positive electrode rings 2, a spiral cylindrical separator 3, a current collector 4, and zinc paste electrolyte 5; the multiple positive electrode rings 2 are axially stacked inside the shell 1, and the spiral cylindrical separator 3 is placed inside the multiple positive electrode rings 2; the bottom of the spiral cylindrical separator 3 abuts against the positive terminal 6; the top seal of the spiral cylindrical separator 3 is inwardly contracted and abuts against the sealing ring 41 of the current collector 4; the spiral cylindrical separator 3 includes three layers of separator paper 31 formed by winding a sheet of separator paper 31, the innermost sealing edge 311 and the outermost sealing edge 312 of the separator paper 31 are axially spiraled and axially spiraled and cross-overlapping; the outermost sealing edge 312 is away from both ends of the spiral cylindrical separator 3; the zinc paste electrolyte 5 is filled inside the spiral cylindrical separator 3.

[0047] It should be noted that the current collector 4 is understood to be the current collector 4 typically found in alkaline zinc-manganese batteries, for example, as shown in the reference... Figure 1As shown, the current collector 4 includes: a sealing ring 41, a current collecting needle 42, and a negative terminal 43; the zinc paste electrolyte 5 is understood to be the zinc paste and electrolyte material commonly used in alkaline zinc-manganese batteries; for example, zinc paste and electrolyte that are matched with the positive electrode.

[0048] For details, please refer to Figure 1 As shown, the sealing ring 41 has an axially recessed abutment groove 411 on the side near the spiral cylindrical diaphragm cylinder 3; the side wall of the abutment groove 411 abuts against the outer side wall of the spiral cylindrical diaphragm cylinder 3 radially; and the top wall of the abutment groove 411 abuts against the top seal of the spiral cylindrical diaphragm cylinder 3.

[0049] The spiral cylindrical diaphragm tube 3 described in this invention is understood to be manufactured using the diaphragm tube manufacturing method provided in Example 2, with reference to... Figure 2 As shown, the height of the spiral cylindrical diaphragm tube 3 can be set to 46mm. The bottom of the spiral cylindrical diaphragm tube 3 is sealed by hot-pressing, and the bottom abuts against the inner side of the positive terminal 6 of the battery. It can isolate and insulate the zinc paste electrolyte 5 inside the spiral cylindrical diaphragm tube 3 from the external positive terminal 6 and positive electrode ring 2.

[0050] The housing described in this invention can be configured as a steel cylinder; it should be noted that the top of the spiral cylindrical diaphragm cylinder 3 is understood as the end near the negative terminal of the battery, and the bottom is understood as the end near the positive terminal of the battery; it should be noted that... Figure 2 The outermost sealing edge 312 and the innermost sealing edge 311 shown also have an intermediate layer with radial thickness. Figure 2 The image only shows the finished winding state of the outermost sealing edge 312 and the innermost sealing edge 311; the middle layer of separator paper 31 is not shown in detail.

[0051] This invention involves subjecting the batteries of Example 1 and Comparative Example 1 to drop, impact, or crush tests under identical conditions. The X-ray image of the battery of Example 1 is shown below. Figure 6 As shown, the X-ray image of the battery in Comparative Example 1 is as follows. Figure 7 As shown; analysis of the test results shows that, without the filling ring 7, the outermost sealing edge 312 of the top seal of the spiral cylindrical diaphragm tube 3 in Example 1 forms a spiral closure, which is more tightly attached to the adjacent inner diaphragm paper 31; Reference Figure 10 As shown, in Comparative Example 1, the outermost ordinary sealing edge 101 of the top seal of the ordinary diaphragm tube 100 has an outward opening, which affects the battery's impact resistance performance; furthermore, the outer opening of the sealing edge at the top of the diaphragm tube in Comparative Example 1 is very close to the side wall of the outer casing 1, which may overlap with the adhesive layer of the steel casing wall, increasing the risk of battery alkali creep and leakage.

[0052] Comparative analysis Figure 6 and Figure 7When the battery described in Example 1 is subjected to external force, such as the spiral cylindrical separator 3, the deformation is almost zero. However, when the battery described in Comparative Example 1 is subjected to external force, the ordinary separator 100 collapses and deforms. It can be seen that the spiral cylindrical separator 3 of Example 1 has stronger resistance to deformation and a lower risk of leakage or short circuit.

[0053] Comparative Example 1:

[0054] This comparative example demonstrates an alkaline zinc-manganese battery. The difference from Example 1 is that the diaphragm tube is made of a common diaphragm tube 100, while the other components are the same as in Example 2.

[0055] Example 2:

[0056] In conjunction with the alkaline zinc-manganese battery with a common diaphragm tube 100 as described in Comparative Example 1, such as Figure 7 As shown, it was found that the positive electrode manganese ring floats when the battery is subjected to external impact. Although the spiral hollow cylindrical separator can improve the battery's drop resistance, the abnormal ΔOV and the floating of the manganese ring still occur after a drop, indicating that the internal structural stability of the battery needs further optimization. Therefore, the structure of the alkaline zinc-manganese battery of the present invention was further optimized through Examples 2 and 3.

[0057] Based on Example 1, in this example, reference is made to... Figure 1 As shown, multiple positive electrode rings 2 are axially stacked on the outside of the spiral cylindrical separator 3 and located inside the shell; specifically, the alkaline zinc-manganese battery also includes a filling ring 7; multiple positive electrode rings 2 are axially stacked along the positive electrode to the negative electrode of the battery; the filling ring 7 is located above the positive electrode ring 2 near the negative electrode of the battery; the inner side of the filling ring 7 is hollow, so that the spiral cylindrical separator 3 can pass through; the upper end of the filling ring 7 abuts against the sealing ring 41; the height of the filled zinc paste electrolyte 5 is equal to the height of the positive electrode ring 2.

[0058] The positive and negative electrodes in this invention are understood to be one end of the positive terminal 6 and one end of the negative terminal 43, respectively. It can be understood that the filling ring 7 of this invention is set close to the negative terminal 43. The spiral hollow membrane section inside the filling ring 7 does not need to be filled with zinc paste and electrolyte, thereby reducing costs and ensuring the stable use of the battery, and thus realizing the manufacture of a low-cost, economical alkaline zinc-manganese battery.

[0059] It should be noted that the filling ring 7 can be made of a material with high cost-effectiveness and a certain degree of hardness. Specifically, the filling ring 7 is composed of at least one of polyimide solid foam, polyetheretherketone, nylon, polytetrafluoroethylene, and silicone resin; for example, refer to Figure 1 and Figure 3 As shown, the filling ring 7 is integrally injection molded from porous polyimide solid foam and has a radially centrally symmetrical structure.

[0060] In this embodiment, at the opening at the upper end of the closed housing of the current collector 4, three positive electrode rings 2 overlap inside the housing, and the height of the positive electrode rings 2 can be selected as 11.0-11.5mm; the filling ring 7 is located on the upper side of the positive electrode ring 2, and the spiral cylindrical diaphragm cylinder 3 is located in the cavity formed by the positive electrode ring 2 and the filling ring 7, which is coaxial with the housing. The negative electrode zinc paste and electrolyte are located inside the spiral cylindrical diaphragm cylinder 3.

[0061] The height setting of the filling ring 7 in this invention can be adjusted according to the performance requirements of the produced battery, thereby meeting production needs. Specifically, in this embodiment, the relationship between the height H1 of the filling ring 7 and the total battery height H is: 0.04H ≤ H1 ≤ 0.5H. Correspondingly, to improve the deformation resistance of the filling ring 7, reference is made to... Figure 1 or Figure 3 As shown, the outer wall of the filling ring 7 is provided with a radially concave arc-shaped groove 71; for example, refer to Figure 3 , Figure 4 and Figure 5 As shown, the filling ring 7 The dimensions are 9.15±0.02mm. The dimensions are 13.60±0.05mm. The size selection range is: The relationship between the height H1 of the filling ring 7 and the total height H of the battery can preferably be set to H1 = 0.2H.

[0062] Specifically, the outer side wall of the filling ring 7 of the present invention is provided with an arc-shaped groove 71 that is concave in the radial direction. The radius of curvature of the arc-shaped groove 71 provided on the side wall of the filling ring 7 is 7.0 mm. The relationship between the height H2 of the arc and the height H1 of the filling ring 7 is H2 = 0.8H1. Similarly, non-arc-shaped groove 71 areas are provided on the upper and lower sides of the side wall of the filling ring 7. The relationship between the height H3 of the non-arc-shaped groove 71 area and the height H1 of the filling ring 7 is H3 = 0.1H1.

[0063] The filling ring 7 in Examples 2 and 3 can effectively reduce the battery's abnormal electrical characteristics after a drop. More preferably, the filling ring 7 has an arc-shaped groove 71 on the side wall, which optimizes the deformation resistance and saves costs.

[0064] Combination Figure 6 , Figure 9 The test results in Table 1 show that the spiral cylindrical diaphragm tube 3 has stronger resistance to deformation. The functions of the filling ring 7 are: first, to support and protect the spiral cylindrical diaphragm tube 3 and prevent it from being squeezed and deformed; second, to isolate the positive and negative electrodes and effectively prevent the zinc paste of the negative electrode from overflowing onto the surface of the manganese ring of the positive electrode after the battery is impacted; and third, to provide a clamping effect on the positive electrode ring 2 in the axial direction and prevent the manganese ring from floating up when the battery is impacted.

[0065] Comparative Example 2:

[0066] This comparative example demonstrates an alkaline zinc-manganese battery. The difference from Example 2 is that the diaphragm tube is made of a common diaphragm tube 100, while the other components are the same as in Example 2.

[0067] Comparative Example 3:

[0068] This comparative example demonstrates an alkaline zinc-manganese battery. Compared to Example 2, it is made using a conventional diaphragm tube, and the outer wall of the filling ring 7 does not have an arc-shaped groove 71. The other components are the same as in Example 2.

[0069] Example 3:

[0070] Based on Example 2, in this example, the height of the positive electrode ring 2 is 12.5-12.9mm, and the arrangement of the other components is the same as in Example 2.

[0071] The alkaline zinc-manganese batteries in Examples 1 to 3 and Comparative Examples 1 to 3 were tested for drop resistance, leakage resistance, and discharge performance. Fifty new batteries were prepared according to the schemes described in the examples and comparative examples. The batteries were dropped from a height of 1 meter onto a cement ground, with the positive electrode, negative electrode, and battery body dropped twice each. The electrical characteristics of the batteries were tested before the drop and after being placed at a constant temperature for 24 hours. The floating of the manganese ring in the batteries was observed using an X-ray fluoroscopy instrument. The number of batteries with abnormal electrical characteristic parameters ΔOV and floating manganese rings were counted. The test results are shown in Table 1.

[0072] Table 1: Statistics on the Number of Batteries with Abnormal Electrical Characteristic Parameter ΔOV and Manganese Ring Floating

[0073] project ΔOV Abnormal Battery Number Number of manganese ring floating batteries Example 1 2 11 Comparative Example 2 1 0 Comparative Example 3 1 0 Example 2 0 0 Example 3 0 0 Comparative Example 1 5 16

[0074] By dissecting the battery with abnormal ΔOV drop in Comparative Example 1 in Table 1, it was found that the negative electrode zinc paste overflowed onto the surface of the casing 1 and the positive electrode ring 2, causing a micro short circuit and slight heating of the battery, which led to abnormal electrical characteristic data after the drop.

[0075] Combining Table 1 and Figure 9 The analysis shows that using the filler ring 7 can effectively reduce battery electrical characteristic abnormalities after a drop. The two types of filler rings 7 have similar effects; however, from a cost perspective, the filler ring 7 with an arc-shaped groove 71 on the sidewall, as shown in Example 2, is more preferred.

[0076] contrast Figure 9 and Figure 8As shown, the battery structures in Examples 2 and 3 are regular, the manganese ring does not float, and the separator tube is not bent or deformed. This indicates that the improved combination of the spiral hollow cylindrical separator tube and the filling ring 7 can prevent abnormal electrical characteristic parameters and manganese ring floating after the battery is dropped, thereby improving the stability of the internal structure of the battery and increasing the reliability of the battery.

[0077] The alkaline zinc-manganese battery provided by this invention has two main advantages. First, it provides a separator tube with stronger resistance to deformation. The spiral cylindrical separator tube 3, formed by winding parallelogram-shaped separator paper, has a spirally closed outermost separator paper sealing edge. The outermost separator paper sealing edge with an inclined angle can fit tightly with the inner separator paper, making it less prone to opening and thus having stronger resistance to deformation. Second, the abutment groove 411 at the lower part of the sealing ring can completely shrink the opening of the separator tube, improving the battery's vibration resistance. When the battery is subjected to impact, the probability of deformation and collapse of the separator tube opening is reduced, preventing the zinc paste from overflowing from the negative electrode and contacting the positive electrode ring, which could lead to an internal short circuit in the battery. Third, the filler ring 7 can fill the space missing from the upper positive electrode ring 2, reducing the degree of deformation of the separator tube when subjected to impact. At the same time, it effectively prevents the zinc paste overflowing from the negative electrode from contacting the positive electrode, avoiding the risk of battery overheating, leakage, or even failure due to internal short circuit. Fourth, the filler ring 7 provides a certain degree of support and clamping in the axial direction for the positive electrode ring 2, preventing the manganese ring from floating when the battery is subjected to impact, and maintaining the stability of the battery's internal structure. Fifth, the height of the filler ring can be adjusted according to the amount of active material filled, and the existing equipment and components meet the production requirements without the need for major modifications or the addition of new equipment.

[0078] The present invention also conducted leakage resistance tests on the zinc-manganese batteries described in the above embodiments and comparative examples, and the test results are shown in Table 2. Leakage resistance test: Ten newly produced batteries were tested for leakage resistance under high temperature of 91℃ (≥30 days) and high temperature and high humidity conditions of 60℃ and RH90% (≥10 weeks).

[0079] As can be seen from the leakage resistance data in Table 2, the spiral cylindrical diaphragm tube 3 of the present invention effectively improves the leakage resistance of the battery. The filling ring 7 is provided in a matching manner, so that the alkaline zinc-manganese battery of the present invention does not leak within a specified time, which greatly improves the leakage resistance of the battery and ensures the reliability of the battery.

[0080] Table 2: Leakage Resistance Test Results of the Battery Described in This Invention

[0081] project 91℃ 60℃, RH 90% undischarged Example 1 No leakage for 30 days, termination. No leakage for 10 weeks, termination. Comparative Example 2 No leakage for 30 days, termination. One animal leaked fluid in week 9, and the treatment was terminated. Comparative Example 3 No leakage for 30 days, termination. Two animals leaked fluid in week 9, termination of treatment. Example 2 No leakage for 30 days, termination. No leakage for 10 weeks, termination. Example 3 No leakage for 30 days, termination. No leakage for 10 weeks, termination. Comparative Example 1 Two animals leaked fluid on day 28, so the treatment was terminated. Two animals leaked fluid in week 9, termination of treatment.

[0082] In contrast, conventional alkaline zinc-manganese batteries, such as those described in Comparative Examples 1 to 3, all exhibited leakage. Upon dissection, it was found that the separator and the open top seal of the separator paper 31 overlapped with the adhesive layer on the inner wall of the steel shell. The electrolyte, rising due to capillary action, caused the adhesive layer to fail, leading to alkaline leakage from the battery.

[0083] The present invention also tested the discharge performance of the alkaline zinc-manganese batteries described in the above embodiments and comparative examples. After aging at 45°C for 2 days according to Embodiments 1 to 3 and Comparative Examples 1 to 3, 9 batteries of each were taken for discharge performance testing. The discharge regime was IEC item. The test results are shown in Table 3.

[0084] The initial discharge performance of the batteries in Examples 1 to 3 and Comparative Examples 1 to 3 shows that the spiral cylindrical separator 3 and the filling ring 7, whether set individually or in combination, have no significant impact on battery performance. Examples 2 and 3 show that increasing the amount of positive electrode active material and increasing the positive electrode height improves the discharge performance under various conditions. The results indicate that in production practice, the size of the filling ring 7 can be adjusted according to the designed battery capacity. Considering both drop resistance and leakage resistance, Examples 2 and 3, with their combined spiral cylindrical separator 3 and filling ring 7, are more preferred options, enabling the production of low-cost alkaline zinc-manganese batteries with higher reliability.

[0085] Table 3: Average Results of Battery Discharge Performance Test

[0086]

[0087] The initial discharge performance of the batteries in the various embodiments and comparative examples shows that the spiral cylindrical separator 3 and the filling ring 7, whether used alone or in combination, have no significant impact on battery performance. Examples 2 and 3 demonstrate that increasing the amount of positive electrode active material and the height of the positive electrode improve the discharge performance under various conditions. These results indicate that the size of the filling ring 7 can be adjusted according to the designed battery capacity in production practice.

[0088] Considering both drop resistance and leakage resistance, the preferred solutions are Examples 2 and 3, in which a spiral cylindrical diaphragm tube 3 is used in combination with a filling ring 7 having an arc-shaped groove 71 on its sidewall. The prototype low-cost alkaline zinc-manganese battery has higher reliability.

[0089] Example 4:

[0090] like Figure 2 and Figure 9 As shown, this embodiment provides a method for manufacturing a separator cylinder for an alkaline zinc-manganese battery, realizing the spiral cylindrical separator cylinder 3 of the alkaline zinc-manganese battery as described in Example 1, including the following steps:

[0091] S1. Adjust the angle of the cutter and cut the diaphragm paper 31 into a parallelogram with an acute angle of α, a base length of L, and a height of H3.

[0092] S2. The acute-angled end of the diaphragm paper 31 is fed into the winding rod 8. The winding rod 8 is rotated to wind the diaphragm paper 31 into a spiral cylindrical diaphragm tube 3, so that the diaphragm paper 31 is a three-layer diaphragm paper 31. The innermost sealing edge 311 and the outermost sealing edge 312 of the diaphragm paper 31 are spirally intersected and overlapped, and the outermost sealing edge 312 is away from both ends of the spiral cylindrical diaphragm tube 3. S3. The bottom of the semi-finished product made in S2 is sealed by the hot-pressing process to form the spiral cylindrical diaphragm tube 3.

[0093] Specifically, such as Figure 2 As shown, the acute angle α is selected in the range of 50° to 80°; the paper feeding direction at one end of the acute angle is perpendicular to the winding direction.

[0094] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. An alkaline zinc-manganese battery, characterized in that, include: The shell (1), multiple positive electrode rings (2), a spiral cylindrical diaphragm tube (3), a current collector (4), and a zinc paste electrolyte (5); the multiple positive electrode rings (2) are axially stacked inside the shell (1), and the spiral cylindrical diaphragm tube (3) is placed inside the multiple positive electrode rings (2); the bottom of the spiral cylindrical diaphragm tube (3) abuts against the positive terminal (6); the top of the spiral cylindrical diaphragm tube (3) is sealed inward and abuts against the sealing ring (41) of the current collector (4); the spiral cylindrical diaphragm tube (3) includes three layers of diaphragm paper (31) formed by winding a diaphragm paper (31), the innermost sealing edge (311) and the outermost sealing edge (312) of the diaphragm paper (31) are axially spiral and cross-over; the outermost sealing edge (312) is away from both ends of the spiral cylindrical diaphragm tube (3); the zinc paste electrolyte (5) is filled inside the spiral cylindrical diaphragm tube (3).

2. The alkaline zinc-manganese battery according to claim 1, characterized in that, The sealing ring (41) has an axially recessed abutment groove (411) on the side near the spiral cylindrical diaphragm cylinder (3); the side wall of the abutment groove (411) abuts radially against the outer side wall of the spiral cylindrical diaphragm cylinder (3); the top wall of the abutment groove (411) abuts against the top seal of the spiral cylindrical diaphragm cylinder (3).

3. The alkaline zinc-manganese battery according to claim 1, characterized in that, It also includes a filling ring (7); multiple positive electrode rings (2) are stacked axially from the positive electrode to the negative electrode of the battery; the filling ring (7) is located above the positive electrode ring (2) near the negative electrode of the battery; the inner side of the filling ring (7) is hollow, so that the spiral cylindrical diaphragm tube (3) can pass through; the upper end of the filling ring (7) abuts against the sealing ring (41); the height of the filled zinc paste electrolyte (5) is equal to the height of the positive electrode ring (2).

4. The alkaline zinc-manganese battery according to claim 3, characterized in that, The relationship between the height H1 of the filling ring (7) and the total height H of the battery is: 0.04H≤H1≤0.5H.

5. The alkaline zinc-manganese battery according to claim 3, characterized in that, The filling ring (7) is composed of at least one of polyimide solid foam, polyether ether ketone, nylon, polytetrafluoroethylene, and silicone resin.

6. The alkaline zinc-manganese battery according to claim 3, characterized in that, The outer wall of the filling ring (7) is provided with an arc-shaped groove (71) that is concave in the radial direction.

7. The alkaline zinc-manganese battery according to claim 6, characterized in that, The relationship between the height H2 of the arc-shaped groove (71) and the height H1 of the filling ring (7) is: H2 = 0.8H1.

8. A method for manufacturing a separator tube for an alkaline zinc-manganese battery, characterized in that, The process of manufacturing the spiral cylindrical separator (3) for the alkaline zinc-manganese battery as described in any one of claims 1-7 includes the following steps: S1. Adjust the angle of the cutter and cut the diaphragm paper (31) into a parallelogram with an acute angle of α, a base length of L, and a height of H3. S2. The acute-angle end of the diaphragm paper (31) is fed into the winding rod (8). The winding rod (8) is rotated to wind the diaphragm paper (31) into a spiral cylindrical diaphragm tube (3), so that the diaphragm paper (31) is a three-layer diaphragm paper (31). The innermost sealing edge (311) and the outermost sealing edge (312) of the diaphragm paper (31) are spirally intersected and overlapped axially. The outermost sealing edge (312) is far away from both ends of the spiral cylindrical diaphragm tube (3). S3. The bottom of the semi-finished product made in S2 is sealed by a hot-seal process to form a spiral cylindrical diaphragm tube (3).

9. The method for manufacturing the separator of the alkaline zinc-manganese battery according to claim 8, characterized in that, The acute angle α is selected from 50° to 80°; the paper feeding direction at one end of the acute angle is perpendicular to the winding direction.

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