Battery with safety mechanism

Abstract

To provide a battery with a safety mechanism adapted to protect against tissue damage and / or electrolysis when the battery is exposed to aqueous solutions or wet tissue.SOLUTION: A battery 50 includes a housing having first and second poles. At least one electronic conductor 66 is electronically coupled to one of the first and second poles. A spacer 64 including an electronically insulating material is provided between the electronic conductor and the other of the first and second poles to prevent electronic coupling between the electronic conductor and the other of the first and second poles. The spacer is capable of undergoing a physical change in the presence of an aqueous solution to allow electronic coupling between the electronic conductor and the other of the first and second poles to occur.SELECTED DRAWING: Figure 2B

Description

Technical Field

[0001] The present disclosure relates to a battery, and more particularly to a battery with a safety mechanism that is adapted to protect against tissue damage and / or electrolysis when the battery is exposed to an aqueous solution or wet tissue.

Background Art

[0002] The description of the background provided herein is generally intended to present the context of the present disclosure.

[0003] An electrochemical cell, often simply referred to as a battery, is generally used as a source of electrical energy. Small batteries are particularly useful in powering consumer products. There are various cell types for small batteries. Common small battery cell types include AAA, AA, B, C, D, 9V, CR2, and CR123A. Another type of small battery known as a button cell (including a wide range of cells sometimes called coin cells) is frequently used to power a variety of products including, but not limited to, wristwatches, cameras, calculators, keyless entry systems for vehicles, laser pointers, glucometers, etc.

[0004] FIG. 1 shows the structure of a representative button cell 10 comprising a cathode 12 disposed within a cathode can 14 and an anode 16 disposed within an anode cup 18. A separator 20 physically separates the anode 16 from the cathode 12 and electrically insulates them. An insulating gasket 22 serves to seal the cell to prevent electrolyte loss and prevent the ingress of ambient air components into the cell and to electrically insulate the cathode can 14 from the anode cup 18. Button cells typically have a long service life, for example, generally far exceeding one year in continuous use in a wristwatch. Further, most button cells have low self-discharge and thus hold their charge for a relatively long time when not under load.

[0005] ​Button cell batteries are common in many portable consumer electronic devices, but the size, shape, and appearance of these batteries, particularly coin-cell batteries with a diameter of 20 mm such as CR2016 lithium cells and CR2032 lithium cells, can pose a risk, especially to infants, toddlers, and pets. These hazards can cause physical harm, especially if the cells are swallowed without the knowledge of others. Furthermore, some of these button cell batteries may pose a relatively greater risk than others, and consumers may not fully understand this risk. For example, 3V coin-cell batteries such as CR2016 3V lithium cells and CR2032 3V lithium cells, based on the chemical reaction between lithium and manganese dioxide, are sized to easily get stuck in a person's throat and, therefore, if swallowed, can cause electrolysis of bodily fluids and / or combustion of moist esophageal / organ tissue. Of course, such batteries can also cause considerable stomach discomfort if swallowed properly. [Overview of the project] [Means for solving the problem]

[0006] A battery is provided with a safety mechanism designed to protect against tissue damage and / or electrolysis. The battery comprises a housing having first and second electrodes. At least one electron conductor is electronically coupled to one of the first and second electrodes. A spacer made of an electronic insulating material is provided between the electron conductor and the other of the first and second electrodes to prevent electronic coupling between the electron conductor and the other of the first and second electrodes. The spacer can be subjected to a physical change in the presence of an aqueous solution so that electronic coupling between the electron conductor and the other of the first and second electrodes may occur.

[0007] Further typical batteries are also provided with safety mechanisms designed to protect against tissue damage and / or electrolysis. The battery with safety mechanisms comprises a housing with first and second electrodes, an electron conductor, and first and second spacers. The first and second spacers are made of an electronically insulating material. The first spacer is positioned between the first electrode of the battery and the electron conductor, and the second spacer is positioned between the second electrode of the battery and the electron conductor, in which case the electron conductor is positioned between the first and second spacers and in contact with these spacers. The spacers can undergo physical changes in the presence of an aqueous solution, and the electron conductor is designed to make electronic contact with both the first and second electrodes in the presence of an aqueous solution.

[0008] This specification concludes with claims that specifically point out and expressly claim the subject matter that is deemed to constitute the present invention, but the present invention will be better understood from the following description, to be interpreted in conjunction with the accompanying drawings. The figures described below illustrate various embodiments of the battery disclosed herein. It should be understood that each figure depicts a typical embodiment of the battery with safety mechanisms that are designed to protect the tissue disclosed herein from damage and / or electrolysis. [Brief explanation of the drawing]

[0009] [Figure 1] This shows a conventional button cell. [Figure 2A] A typical embodiment of the present disclosure is shown, which is a coin cell-shaped battery having a safety mechanism that protects against tissue damage and / or electrolysis. [Figure 2B] A typical embodiment of the present disclosure is shown, which is a coin cell-shaped battery having a safety mechanism that protects against tissue damage and / or electrolysis. [Figure 3]The cell voltage versus time plots for two different batteries are shown, the first being a conventional coin cell battery and the second being a coin cell battery having a safety mechanism that protects against tissue damage and / or electrolysis according to a typical embodiment of the present disclosure. [Figure 4A] Other batteries in the form of coin cells having safety mechanisms that protect against tissue damage and / or electrolysis, as described in other typical embodiments of this disclosure, are also shown. [Figure 4B] Other batteries in the form of coin cells having safety mechanisms that protect against tissue damage and / or electrolysis, as described in other typical embodiments of this disclosure, are also shown. [Figure 5A] Further typical embodiments of this disclosure include other batteries in the form of coin cells having safety mechanisms that protect against tissue damage and / or electrolysis. [Figure 5B] Further typical embodiments of this disclosure include other batteries in the form of coin cells having safety mechanisms that protect against tissue damage and / or electrolysis. [Figure 6A] Other batteries in the form of coin cells having safety mechanisms that protect against tissue damage and / or electrolysis, as described in other typical embodiments of this disclosure, are also shown. [Figure 6B] Other batteries in the form of coin cells having safety mechanisms that protect against tissue damage and / or electrolysis, as described in other typical embodiments of this disclosure, are also shown. [Figure 7] Other batteries in the form of coin cells having safety mechanisms that protect against tissue damage and / or electrolysis, as described in other typical embodiments of this disclosure, are also shown. [Figure 8] Other batteries in the form of coin cells having safety mechanisms that protect against tissue damage and / or electrolysis, as described in other typical embodiments of this disclosure, are also shown. [Modes for carrying out the invention]

[0010] An electrochemical cell or battery may be a primary battery or a secondary battery. A primary battery is designed to be discharged only once until it is depleted and then discarded. Primary batteries are described, for example, in David Linden's Handbook of Batteries (McGraw-Hill, 4th edition, 2011). A secondary battery is designed to be rechargeable. A secondary battery can be discharged and then recharged many times, for example, more than 50 times, more than 100 times, or more than 1000 times. Secondary batteries are described, for example, in David Linden's Handbook of Batteries (McGraw-Hill, 4th edition, 2011). The battery may contain water-soluble or water-insoluble electrolytes. Therefore, the battery may contain various combinations of electrochemical bonds and electrolytes. A consumer battery may be either a primary battery or a secondary battery. However, due to the charge stored in the battery and the exposed electrodes, it is beneficial to protect consumer batteries, especially small consumer batteries, from harm to consumers when exposed to moist tissue. In particular, it is beneficial to protect the battery from exposure to electrolysis or burns, both of which can occur, for example, if the battery is swallowed. In this regard, if the positive and negative electrodes of a battery are exposed to moist bodily fluids, electrolysis of water may occur, leading to the release of hydroxide ions and combustion of tissue adjacent to the negative electrode, and potentially causing direct oxidation of tissue, especially tissue adjacent to the positive electrode (or cathode can). In addition, significant oxidation of the cathode can itself may lead to the formation of holes in the cathode can, thereby releasing the toxic contents of the battery. This application provides a safety mechanism for short-circuiting a battery in the presence of an aqueous solution. By short-circuiting the battery in the presence of an aqueous solution, the disclosed safety mechanism favorably reduces the cell voltage of the swallowed battery, thereby effectively preventing tissue damage and other harmful effects caused by uncontrolled discharge of the swallowed battery.

[0011] A battery is provided with safety mechanisms designed to protect against tissue damage and / or electrolysis. The battery includes a battery housing comprising first and second electrodes. At least one electron conductor is electronically coupled or in electronic contact with one of the first and second electrodes. It should be noted that the terms “electronically coupled” and “electron contact” are used interchangeably herein to describe relationships in which electron flow may occur between the listed components. The electron conductor may be electronically coupled to one of the first and second electrodes because the electron conductor is in direct physical contact with the electrode. Alternatively, one or more further intervening electron-conducting materials may be present between the electron conductor and one of the first and second electrodes.

[0012] A spacer comprising an electronic insulating material is provided between the electronic conductor and the other of the first and second poles to prevent electronic coupling between the electronic conductor and the other of the first and second poles. The spacer can undergo physical changes (including, but not limited to, chemical changes that result in changes in physical properties) in the presence of an aqueous solution so that electronic coupling between the electronic conductor and the other of the first and second poles may occur.

[0013] Generally, this disclosure provides batteries that can be mechanically and / or electronically short-circuited by electronically coupling both battery electrodes or by forming an electronic connection across both battery electrodes. The electronic connection across the positive and negative battery electrodes is formed only after the battery has been exposed to “safe conditions,” where “safe conditions” refers to the ambient conditions the battery faces when it comes into contact with the throat of a person, infant, or pet animal. In these situations, if a person, infant, or pet animal swallows the battery, the battery may come into contact with saliva, gastric juice, or other aqueous fluids. Therefore, batteries with safety mechanisms designed to protect against tissue damage and / or electrolysis are designed to be short-circuited in the presence of aqueous solutions. The resulting short circuit can reduce the battery voltage to below a desired threshold level, thereby reducing and / or effectively preventing the electrolysis of water and the formation of harmful ions (e.g., hydroxide ions) that are produced electrochemically. The desired threshold level can vary, but in some examples detailed herein, the cell can preferably be short-circuited down to less than 1.5V, including less than 1.4V, less than 1.3V, less than 1.2V, less than 1.1V, less than 1.0V, less than 0.9V, less than 0.8V, less than 0.7V, less than 0.6V, less than 0.5V, less than 0.4V, less than 0.3V, less than 0.2V, and less than 0.1V, and even down to about 0V. Under “normal operating conditions,” such as when the battery is not in use, for example, when the battery is being stored or transported, or when the battery is operating in an electronic device, the formation of electronic connections does not occur and a short circuit of the battery is avoided.

[0014] In one embodiment, the battery according to the present disclosure includes an electron conductor that is initially in electronic contact with only one of the first and second electrodes of the battery. A spacer comprising an electronic insulating material prevents the electron conductor from making electronic contact across both battery electrodes under normal operating conditions (i.e., before the battery is in contact with an aqueous solution). On the other hand, when the battery is exposed to or in contact with an aqueous solution such as saliva, gastric juice, water, or other aqueous fluid, the electronic insulating material may undergo a physical change, for example, it may dissolve. This is because the electronic insulating material dissolves in the aqueous fluid. The electron conductor is biased toward electronic contact with the other electrode of the battery, but the resistive force of the spacer is greater than the biasing force of the electron conductor under normal operating conditions. However, after the substantial dissolution of the electronic insulating material, such resistive force is substantially absent, and the electron conductor may make electronic contact with the other electrode of the battery, thereby potentially short-circuiting the battery. The electron conductor may be biased, for example, during the crimping of the cathode can (or its extension) and / or during the crimping of an electron conductor that is a separate component from the cathode can.

[0015] In other examples, the battery according to the present disclosure also includes an electron conductor that is initially in electronic contact with only one of the first and second electrodes of the battery. A spacer comprising an electronic insulating material prevents the electron conductor from making electronic contact across both battery electrodes under normal operating conditions (i.e., before the battery is in contact with an aqueous solution). On the other hand, when the battery is exposed to or in contact with an aqueous solution such as saliva, gastric juice, water, or other aqueous fluid, the electronic insulating material may undergo physical changes, for example, it may swell and / or soften in the presence of the aqueous fluid. This is because the electronic insulating material comprises a polymer that swells when exposed to an aqueous solution. The electron conductor is biased toward electronic contact with the other electrode of the battery, but the resistive force of the spacer is greater than the biasing force of the electron conductor under normal operating conditions. However, after swelling and / or softening of the electronic insulating material, the resistive force of the spacer is significantly reduced, which may result in mechanical deformation, strain, or displacement of the spacer. This is because the biasing force of the electron conductor "overcomes," deforms, or displaces the electron insulating material of the spacer, thereby creating an electronic connection between the two poles and short-circuiting the battery. In one improvement, the electron insulating material is a hydrogel that forms a gel that cannot resist the biasing force given by the electron conductor in the presence of an aqueous fluid. The electron conductor can be biased, for example, during the crimping of the cathode can (or its extension) and / or during the crimping of an electron conductor that is a separate component from the cathode can.

[0016] As an example, the electronic conductor in the present specification may be formed of a metal. For example, the electronic conductor may be formed of any suitable electronic conductive material. Suitable electronic conductive materials for forming the electronic conductor include, but are not limited to, (i) metal alloys including steels such as stainless steel, nickel-plated steel, or zinc-plated steel, (ii) conductive ceramics including carbides, oxides, nitrides, and combinations thereof, (iii) conductive polymers, (iv) conductive composites, and any combination thereof, but are not limited thereto. The electronic conductor may be energized, for example, during the crimping of the cathode can (or its extension) and / or during the crimping of the electronic conductor that is a separate component from the cathode can.

[0017] The electronic conductor disclosed in the present specification generally has a resistance value of less than about 5×10

[0018] ,

[0019] , , , ohm·cm at 20°C or less than 2.5×10 -5 ohm·cm at 20°C, or less than about 0.5×10 -5 ohm·cm to about 5×10 -5 ohm·cm at 20°C. In some examples, the resistance of the electronic conductor is less than 20 ohms, less than 10 ohms, or less than 5 ohms. For example, the resistance may be about 10 ohms, about 5 ohms, or about 1 ohm, etc. In some examples, the resistance of the electronic conductor is from about 0.1 ohm to about 20 ohms.

[0018] The resistance of the electronic insulating material is always greater than the resistance of the electronic conductor. In some examples, the resistance of the electronic insulating material is greater than 0.5 megaohm, greater than 5 megaohm, greater than 10 megaohm, greater than 100 megaohm, or greater than 500 megaohm. For example, the resistance of the electronic insulating material may be about 1 megaohm, about 20 megaohm, about 200 megaohm, or about 1000 megaohm, etc. In some examples, the resistance of the electronic conductor is from about 0.5 megaohm to about 1000 megaohm.

[0019] The electronic insulating material of the spacer may be formed from any number of electronic insulating materials that can undergo physical changes in the presence of water, including but not limited to suitable water-softening materials and suitable water-soluble and / or water-swelling materials (including but not limited to electronic insulating materials that undergo chemical changes leading to changes in physical properties). As used herein, the term “water-softening” refers to a material that has a Young’s modulus that decreases in the presence of an aqueous solution. Useful water-softening materials have a Young’s modulus that is high enough to provide a resistance greater than the biasing force of an electron conductor under normal operating conditions. Useful water-softening materials also have a Young’s modulus that is low enough after exposure to an aqueous solution to allow the material to deform sufficiently when the biasing force of an electron conductor is applied to the water-softening material, thereby enabling an electronic coupling between the electron conductor and the other of the first and second battery electrodes. Useful water-softening materials also generally have a Young’s modulus that decreases to a range of 0.0003 to 0.15 GPa after exposure to an aqueous solution. Various test systems can be used to determine the modulus of elasticity, for example, the 8802 servo hydraulic test system available from Instron. The water-softening material may be a water-soluble material. Useful water-soluble materials have a water solubility greater than 50 mg / L, greater than 100 mg / L, greater than 500 mg / L, or even greater than 1000 mg / L. Useful water-swellable materials are generally absorbable in pure water in amounts greater than 30 wt.%, preferably at least 100 wt.%, of water. Useful water-swellable materials allow the material to deform sufficiently when the biasing force of an electron conductor is applied to the water-swellable material after the presence of an aqueous solution, thereby bringing about an electronic coupling between the electron conductor and the other of the first and second battery electrodes.

[0020] The electronic insulating material may be present in amounts of 5 wt.% to 100 wt.%, for example, 10 wt.% to 99 wt.%, 50 wt.% to 99 wt.%, and / or 70 wt.% to 99 wt.%, based on the weight of the spacer (i.e., based on the weight of the solid used to provide the spacer). Any number of water-softening, water-soluble, and / or water-swellable polymers may be used alone or in combination to form the spacer. Non-limiting examples of water-soluble, water-soluble, and / or water-swellable materials include, but are not limited to, sugars, polyethers such as polyethylene glycol (PEG) and polyethylene oxide (PEO), polyacrylic acid (PAA), polyamide (PA), polyacrylates, polyvinyl alcohol and modified polyvinyl alcohol, acrylate copolymers, polyvinylpyrrolidone, pullulan, gelatin, carboxymethylcellulose (CMC), hydroxypropylmethylcellulose (HPMC), hydroxypropylcellulose, polysaccharides, natural polymers including but not limited to agar, guar gum, xanthan gum, locust bean gum, carrageenan, and modified starches including but not limited to starch, ethoxylated starch and hydroxypropylated starch, the aforementioned copolymers, their salts, and any combination thereof. Water-softening, water-soluble, and / or water-swellable materials are preferably biologically inert materials that are non-toxic or nearly non-toxic.

[0021] Beneficial solids such as NaHPO4, sodium chloride (NaCl), potassium chloride (KCl), baking soda, sugar, sugar-like substances, and citric acid may be included in combination with the electronic insulating material to provide spacers. The benevolent solids may be present in amounts of 0 wt.% to 30 wt.%, for example, 0 wt.% to 20 wt.%, 1 wt.% to 30 wt.%, and / or 1 wt.% to 20 wt.%, based on the weight of the spacers (i.e., based on the weight of the solids used to provide the spacers).

[0022] Figures 2A and 2B show a battery 50, which may be any type of primary or secondary battery, and in the illustrated example, is a button cell type battery. The battery 50 includes a battery housing that surrounds the battery. The battery housing comprises a cathode can 54 and an anode cup 58. The cathode 52 is located in the cathode can 54 and the anode 56 is located in the anode cup 58. The cathode 52 and anode 56 are electronically separated by a separator 60 in the battery 50. The cathode can 54 and anode cup 58 each form a different pole of the battery 50, in which case the cathode can 54 forms the positive pole and the anode cup 58 forms the negative pole.

[0023] The cathode 52 and anode 56 are separated by an insulating separator 60 that extends over the entire lateral range of the cathode 52, for example, substantially over the entire diameter of the battery 50. The insulating separator 60 is made of a material through which ions can freely conduct. An insulating gasket 62 electronically insulates the cathode can 54 from the anode cup 58, and the insulating gasket 62 seals the battery 50 and prevents electrolyte loss by preventing any part of the anode cup 58 from coming into contact with the cathode can 54.

[0024] In the illustrated embodiment, the insulating gasket 62 extends into the cathode can 54 to completely surround the anode cup 58 so that the anode cup cannot come into contact with the cathode can 54, but the reverse configuration may be used in which the anode cup 58 surrounds the cathode can 54 and the insulating gasket 62 extends into the anode cup 58 to completely surround the cathode can 54. Each illustrated embodiment explicitly shown herein (including those shown in Figures 2A, 2B, 4A, 4B, 5A, 5B, 6A, and 6B) includes an insulating gasket 62 (or corresponding reference number) that extends into the cathode can 54 (or corresponding reference number) to completely surround the anode cup 58 (or corresponding reference number) so that the anode cup cannot come into contact with the cathode can 54 (or corresponding reference number), but it should be understood that batteries with safety mechanisms in which the reverse configuration is used are conceivable.

[0025] The battery 50 further includes a typical safety mechanism designed to protect the tissue relating to this disclosure from damage and / or electrolysis, the safety mechanism including an electron conductor 66 extending whole or partially around the outer edge of the cathode can 54. The electron conductor 66 may be formed from a metal, such as a metal alloy material, as described above. The electron conductor 66 includes a mounting segment 68 that is attached and fixed to the outer surface of the cathode can 54. The electron conductor 66 may be attached to the cathode can by any suitable interconnection. For example, the mounting segment 68 may be attached by an interference fit with a groove (not shown) along the outer wall of the cathode can 54 for mechanically secure attachment. In other examples, the mounting segment 68 may be attached to the outer wall of the cathode can 54 by applying an adhesive or by forming a welded joint.

[0026] In the reverse configuration (not shown, briefly described above) in which the insulating gasket 62 extends into the anode cup 58 and surrounds the cathode can 54 so that the cathode can cannot come into contact with the anode cup 58, the electron conductor 66 may extend entirely or partially around the outer edge of the anode cup 58 and be fixed to the anode cup as described above in relation to the cathode can 54.

[0027] As shown in Figure 2B, the mounting segment 68 of the electron conductor 66 is electronically coupled to the cathode can 54. In the illustrated configuration, the electron conductor 66 is in direct physical contact with the cathode can 54. The electron conductor 66 further includes a grounding segment 70 extending from the mounting segment 68. Generally, the grounding segment 70 extends in a direction perpendicular or substantially perpendicular to the mounting segment 68.

[0028] The grounding segment 70 is separated from the anode cup 58 during the normal operation of the battery 50, thereby preventing the positive and negative terminals from being electronically coupled during the normal operation of the battery 50, and consequently preventing a short circuit of the battery 50. In the illustrated example, the spacing between the grounding segment 70 and the anode cup 58 is achieved by providing a spacer 64 comprising an electronically insulating material between the grounding segment 70 and the anode cup 58. As shown in Figure 2B, the spacer is positioned between the protruding portion of the grounding segment 70 and the other of the first and second terminals, in this case the anode cup 58, so that the grounding segment 70 of the electronic conductor 66 does not electronically couple to the anode cup 58 (and therefore the negative terminal of the battery 50) when the spacer 64 is present, as in normal operating conditions. The spacer 64 may extend to or beyond the leading protruding portion of the grounding segment 70.

[0029] The spacer 64 may be made of a material that can undergo physical changes, for example, by dissolving after being exposed to a safe state, generally after being exposed to saliva, gastric juice, or other aqueous fluids, so that after the dissolution of the spacer 64, the biasing force of the electron conductor 66 can cause the ground segment 70 to electronically contact the anode cup 58 (e.g., its upper end face or side wall face) and short-circuit the battery 50. In other examples, the spacer 64 may be made of a material that can be overcome, deformed, or displaced, so that the spacer 64 softens, swells, or otherwise becomes mechanically brittle in response to being exposed to a safe state, generally saliva, gastric juice, or other aqueous fluids. The spacer 64 may be mechanically brittle when, for example, an aqueous fluid comes into contact with the battery 50 and is absorbed by the spacer 64, causing the spacer 64 to soften, swell, and / or form a gel. As a result of such mechanical weakening of the spacer 64, the biasing force of the electron conductor 66 can engage the ground segment 70 with the anode cup 58, causing it to make electronic contact, thereby short-circuiting the battery 50, for example, in a safe state (or other contact between the battery 50 and an aqueous fluid). As previously stated, a safe state may occur when a person, infant, or pet animal swallows the battery 50 and exposes it to an aqueous solution in the form of saliva or gastric juice. In the illustrated embodiment, the insulating gasket 62 is shown as a separate component from the spacer 64, so that it can remain intact after the battery 50 comes into contact with an aqueous fluid and the spacer undergoes physical changes, thereby retaining the materials of the cathode 52 and anode 56 within the battery 50. However, in other embodiments, the insulating gasket 62 and the spacer 64 can form an integrated structure, in which case the spacer 62 also functions as the insulating gasket 64, effectively providing the insulating gasket 64. Therefore, in this embodiment, there is no separate insulating gasket 64, and the spacer 62, which comprises the electronic insulating material, is positioned between the ground segment 70 and the anode cup 58, and also extends into the cathode can 54 to completely surround the anode cup 58, so that the anode cup 54 cannot come into contact with the cathode can 54.Of course, as mentioned above, batteries with safety mechanisms that use the reverse configuration are conceivable.

[0030] As illustrated in the example shown in Figure 2B, the electron conductor 66 includes two segments, namely a mounting segment 68 and a grounding segment 70. Each segment 68, 70 is electronically coupled to a first pole of the battery 50 (e.g., a cathode can 54), and each segment 68, 70 is electronically isolated from a second pole of the battery 50 (e.g., an anode cup 58) by a spacer 64. In the illustrated embodiment, the mounting segment 68 is electronically coupled (actually making direct physical contact) to the cathode can 54, i.e., the positive battery pole, and the grounding segment 70 of the electron conductor 66 does not electronically contact the anode cup 58, i.e., the negative battery pole, but is biased in a direction to engage with the anode cup 58.

[0031] It is found that it is sufficient for either the positive or negative terminal of the battery 50 to be electronically connected to the electron conductor 66, in which case the other of the two terminals is electronically insulated from the electron conductor 66, which is under tension under normal use or storage conditions. Therefore, it is further found that a spacer 64 may be placed adjacent to either the positive or negative terminal of the battery 50 to prevent electronic contact between the electron conductor 66 and either the positive or negative terminal of the battery 50 under normal use or storage conditions. Therefore, another method is also conceivable: the electron conductor 66 may be arranged around the battery 50 such that it is electronically coupled to the upper end surface of the anode cup 58 during normal use (for example, making direct physical contact) and is separated from the side wall of the cathode can 54 by a spacer 64 placed between the electron conductor 66 and the cathode can 54.

[0032] Furthermore, in the illustrated example, the mounting segment 68 and the grounding segment 70 are shown to form a single unit and therefore directly connected to each other so that they are continuously electronically coupled to one another. However, in other examples, the mounting segment 68 and the grounding segment 70 of a battery safety mechanism (not shown) may be electronically isolated from each other during normal operation of the battery so that they are electronically coupled to each other only in the presence of, for example, an aqueous solution or bodily fluid, during a safety condition. Thus, in other examples, the mounting segment 68 may be in electronic contact with either the positive or negative terminal of the battery 50, and the grounding segment 70 may be in electronic contact with the other of the positive and negative terminals of the battery 50, in which case the spacer 64 comprises insulating material positioned between the two segments 68, 70 so that the segments 68, 70 are not electronically coupled to each other during normal operation of the battery (and therefore the positive and negative terminals are not electronically coupled to each other). After facing a safety condition (or other contact between the battery 50 and an aqueous fluid) that results in the dissolution, softening, and / or swelling of the electronic insulating material of the spacer 64, the grounding segment 70 can engage with the mounting segment 68 and make electronic contact, thereby short-circuiting the battery 50. As previously stated, a safety condition may occur when a person, infant, or pet animal swallows the battery 50 and exposes the battery 50 to an aqueous solution in the form of saliva or gastric juice.

[0033] Figure 3 shows cell voltage versus time plots for two different batteries: a conventional button cell battery (in this example, the DL2032 button cell battery available from Duracell Inc.) and an equivalent button cell battery, such as battery 50 depicted in Figures 2A and 2B, which further includes safety mechanisms designed to protect against tissue damage and / or electrolysis according to this disclosure. After the battery is in contact with a 1M KCl solution for approximately 100 seconds, gas is supplied to the anode cup 58, and the actual cell voltage of the tested battery drops as the battery begins to short-circuit. In the conventional battery, the voltage drop stops at approximately 1.5V after approximately 300 seconds. A voltage of 1.5V, though dropped, is sufficient to cause the electrolysis of water and the generation of hydroxide ions. Therefore, even though this voltage drops, if the battery remains in the human throat, it can cause burning and damage to esophageal tissue. Of course, if the battery is swallowed properly, it can also cause considerable stomach discomfort. In contrast, the battery 50, which has a safety mechanism designed to protect against tissue damage and / or electrolysis, is further short-circuited so that the electrolysis of water does not substantially occur anymore at the anode cup 58. In fact, in the illustrated example, the safety mechanism short-circuits the battery 50 substantially completely to nearly 0V. In the example shown in Figure 3, a spacer 64 was used which comprises an electronically insulating material that is a water-soluble material that can dissolve in saliva, gastric juice, or other aqueous fluids. Specifically, the spacer 64 of the battery 50 with the safety mechanism shown in Figure 3 contained a benign solid, in this case a benign salt, specifically NaHPO4 (about 10 wt.%), and a water-soluble material, specifically polyacrylic acid (about 90 wt.%).

[0034] In Figures 4A and 4B, another example of battery 100, also shown as a button cell battery, includes a cathode can 114 and an anode cup 118. The cathode 152 is located in the cathode can 114 and the anode 156 is located in the anode cup 118. The cathode 152 and anode 156 are electronically separated by a separator 160 in the battery 100. The cathode can 114 and anode cup 118 each form a different pole of the battery 100, in this case the cathode can 114 forms the positive pole and the anode cup 118 forms the negative pole. An insulating gasket 162 electronically insulates the cathode can 114 from the anode cup 118, and the insulating gasket 162 seals the battery 100 and prevents electrolyte loss by preventing any part of the anode cup 118 from coming into contact with the cathode can 114. Battery 100 shares many of the same elements as those shown in Figures 2A and 2B in relation to battery 50, and therefore, generally speaking, only the differences are described herein.

[0035] The battery 100 further includes a safety mechanism designed to protect against tissue damage and / or electrolysis, the safety mechanism comprising a spacer 164 and an electronic conductor 166 embedded or positioned within the spacer 164, the spacer 164 comprising an electronic insulating material that can undergo physical changes after exposure to an aqueous solution such as saliva, gastric juice, water, or other aqueous fluid. The spacer 164 is positioned above the insulating gasket 162 and functions similarly to the insulating gasket 162 during normal operation in that the spacer 164 electronically insulates the cathode can 114 from the anode cup 118. In the illustrated example, the electronic conductor 166 embedded or positioned within the spacer 164 makes direct physical contact with one of the first and second battery electrodes, in this case the anode cup 118, and is therefore electronically coupled to the anode cup 118, but is electronically isolated by the spacer 164 from the other of the first and second battery electrodes, in this case the cathode can 114. In this example, the electron conductor 166 is electronically coupled to the anode cup 118 at the contact position 150. Similar to the electronic coupling between the cathode can 54 and the electron conductor 66 exemplified in the battery 50 shown in Figures 2A and 2B, the electronic coupling between the electron conductor 166 and the anode cup 118 can be a predetermined direct physical connection that is maintained throughout the operation of the battery 100, both during normal operation and storage, and after the battery 100 has reached a safe state. The connection between the electron conductor 166 and the anode cup 118 at the contact position 150 can be fixed, for example, by welding or mechanical connection.

[0036] In the illustrated embodiment, the electron conductor 166 extends from the contact position 150 to two branched arm segments that are biased toward engaging with the cathode can 114, traversing a portion of the distance between the anode cup 118 and the cathode can 114. In this example, only a single electron conductor 166 is shown, but one or more such electron conductors 166 may be included. After contact with an aqueous solution such as saliva, gastric juice, water, or other aqueous fluid, dissolution, softening, and / or swelling of the spacer 164 occurs, thereby allowing the electron conductor 166 to deflect toward electronic contact with the cathode can 114, resulting in the cathode can 114 being electronically coupled to the anode cup 118. As a result, the battery 100 is short-circuited, and the consumer is protected in a safe state, for example, if the battery 100 is swallowed by a person or pet animal. In the illustrated embodiment, the insulating gasket 162 is shown as a separate component from the spacer 164, so that the battery 100 can remain intact after contact with the aqueous fluid, thereby retaining the cathode 152 and anode 156 material within the battery 100. However, in other embodiments, the insulating gasket 162 and the spacer 164 can form an integrated structure, in which case the spacer 164 further functions as the insulating gasket 162, as mentioned above with respect to the spacer 64 and insulating gasket 62 in relation to Figures 2A and 2B, thereby effectively providing the insulating gasket 162.

[0037] In this example, the electron conductor 166 may be partially or completely embedded or positioned within the spacer 164, as long as the resistance of the spacer 164 is greater than or equal to the biasing force of the electron conductor 166 so that the electron conductor does not bias toward electronic contact with the cathode can 114 under normal operating conditions. Therefore, it should be noted that the electron conductor 166 may be biased toward engaging with the cathode can 114, for example, toward engaging with the inner surface of the cathode can 114. Of course, the opposite configuration is also conceivable, in which the electron conductor 166 is electronically coupled to the cathode can 114 by making direct physical contact with the cathode can 114, while being electronically separated from the anode cup 118 by the spacer 164.

[0038] Figures 5A and 5B show a typical battery 200 with safety mechanisms according to this disclosure that are designed to protect against tissue damage and / or electrolysis. The battery 200 includes a cathode can 214 and an anode cup 218. A cathode 252 is located in the cathode can 214 and an anode 256 is located in the anode cup 218. The cathode 252 and anode 256 are electronically separated by a separator 260 in the battery 200. The cathode can 214 and anode cup 218 each form a different pole of the battery 200, in this case the cathode can 214 forms the positive pole and the anode cup 218 forms the negative pole. An insulating gasket 262 electronically insulates the cathode can 214 from the anode cup 218, and the insulating gasket 262 seals the battery 200 by preventing any part of the anode cup 218 from coming into contact with the cathode can 214, thereby preventing electrolyte loss. Battery 200 shares many of the same elements as those shown in Figures 2A and 2B in relation to battery 50, and therefore, generally speaking, only the differences are described herein.

[0039] The first battery electrode, in this case the cathode can 214, includes an electron conductor 230 incorporated into the cathode can 214 as a continuous or extended portion. Thus, although the electron conductor 66 is shown as a separate component from the cathode can 54 in Figure 2B, the electron conductor 230 and the cathode can 214 form a single structure, and for example, the electron conductor 230 constitutes a continuous or extended portion of the cathode can 214 that can be electronically coupled to the outer surface of the second battery electrode, in this case the anode cup 218, to short-circuit the battery 200 after the battery has been exposed to an aqueous solution such as saliva, gastric juice, water, or other aqueous fluid. The electron conductor 230 may have protrusions (not shown) that facilitate electronic contact with the outer wall of the other battery electrode, the anode cup 218, after the battery 200 has been brought to a safe state.

[0040] In the embodiments shown in Figures 5A and 5B, the electron conductor 230 of the cathode can 214 is separated from the anode cup 218 by a spacer 264 comprising an electronically insulating material. The spacer 264 is incorporated into a sealed region of the battery 200 and is positioned between the electron conductor 230 and the outer wall of the anode cup 218, thereby preventing electronic contact between the electron conductor 230 and the anode cup 218. Under normal operating conditions, the spacer 264 may also provide a further seal to the battery 200, including a common insulating gasket 262 as described above. The spacer 264 and the insulating gasket 262 work together to prevent electronic connection between the anode cup 218 and the cathode can 214, thereby electronically insulating these two components from each other under normal operating conditions. After the battery 200 is exposed to an aqueous solution or bodily fluid, the dissolution, softening, and / or swelling of the electronic insulating material of the spacer 264 can cause the continuous or extended portion 230 of the cathode can 214 to be biased in a direction that engages with the outer wall of the anode cup 218, thereby allowing the continuous or extended portion 230 of the cathode can 214 to be electronically coupled to the anode cup 218. As a result, the consumer is protected in a safe state, for example, if the battery 200 is short-circuited or swallowed by a person or pet. In the illustrated embodiment, the insulating gasket 262 is shown as a separate component from the spacer 264, so that it can remain intact after the battery 200 comes into contact with an aqueous fluid, thereby allowing the materials of the cathode 252 and anode 256 to be retained within the battery 200. However, in other embodiments, the insulating gasket 262 and the spacer 264 can form an integrated structure, in which case the spacer 264 further functions as the insulating gasket 262, as mentioned above with respect to the spacer 64 and insulating gasket 62 in relation to Figures 2A and 2B, thereby effectively providing the insulating gasket 262.

[0041] Generally, the continuous or extended portion 230 forming an integral part of the cathode can 214 is formed during the crimping process when the battery 200 is manufactured. In the illustrated example, the continuous or extended portion 230 of the cathode can 214 is formed as an extension of the side wall of the cathode can 214. The continuous or extended portion 230 includes a bend and is biased toward a direction that engages with the anode cup 218. The continuous or extended portion 230 may be pre-cut, for example, to form a biased electron conductor.

[0042] Figures 6A and 6B show a typical battery 300 with safety mechanisms according to this disclosure that are designed to protect against tissue damage and / or electrolysis. The battery 300 includes a cathode can 314 and an anode cup 318. A cathode 352 is located in the cathode can 314 and an anode 356 is located in the anode cup 318. The cathode 352 and anode 356 are electronically separated by a separator 360 in the battery 300. The cathode can 314 and anode cup 318 each form a different pole of the battery 300, in this case the cathode can 314 forms the positive pole and the anode cup 318 forms the negative pole. An insulating gasket 362 electronically insulates the cathode can 314 from the anode cup 318, and the insulating gasket 362 seals the battery 300 and prevents electrolyte loss by preventing any part of the anode cup 318 from coming into contact with the cathode can 314. Battery 300 shares many of the same elements as those shown in Figures 2A and 2B in relation to Battery 50, and therefore, generally speaking, only the differences are described herein.

[0043] Battery 300 has similar features to batteries 100 and 200 (shown in Figures 3A, 3B, 4A, and 4B). As shown in Figure 6B, battery 300 differs from battery 200 in that its safety mechanism includes a second electron conductor 366, which may be embedded or positioned within the spacer 364, extend around the entire circumference of the anode cup 318, or extend only along a portion of the outer circumference of the anode cup 318. The second electron conductor 366 is electronically coupled to the anode cup 318 by making direct physical contact with it, while being electronically separated from the first conductor 330 and therefore the cathode can 314 by the spacer 364. After the battery 300 is exposed to an aqueous solution or bodily fluid, the continuous or extended portion 330 of the cathode can 314 can be biased to engage with the outer wall of the anode cup 318 when the electronic insulating material of the spacer 364 dissolves, softens, and / or swells, thereby enabling the continuous or extended portion 330 of the cathode can 314 to be electronically coupled to the anode cup 318. In addition, after the battery comes into contact with an aqueous solution such as saliva, gastric juice, water, or other aqueous fluid, the electron conductor 366 can be deflected to electronic contact with the cathode can 314, thereby enabling the cathode can 314 to be electronically coupled to the anode cup 318. As a result, consumers are protected in a safe state, for example, if the battery 300 is short-circuited and swallowed by a person or pet. In the illustrated embodiment, the insulating gasket 362 is shown as a separate component from the spacer 364, so that the battery 300 can remain intact after contact with the aqueous fluid, thereby retaining the cathode 352 and anode 356 material within the battery 300. However, in other embodiments, the insulating gasket 362 and the spacer 364 can form an integrated structure, in which case the spacer 364 further functions as the insulating gasket 362, as mentioned above with respect to the spacer 64 and insulating gasket 62 in relation to Figures 2A and 2B, thereby effectively providing the insulating gasket 362.

[0044] Figure 7 shows a further typical battery 400 with safety mechanisms according to the present disclosure that are designed to protect against tissue damage and / or electrolysis. The battery 400 includes a cathode can 414 and an anode cup 418. A cathode 452 is located in the cathode can 414 and an anode 456 is located in the anode cup 418. The cathode 452 and anode 456 are electronically separated by a separator 460 in the battery 400. The cathode can 414 and anode cup 418 each form a different pole of the battery 400, in this case the cathode can 414 forms the positive pole and the anode cup 418 forms the negative pole. An insulating gasket 462 electronically insulates the cathode can 414 from the anode cup 418, and the insulating gasket 462 seals the battery 400 and prevents electrolyte loss by preventing any part of the anode cup 418 from coming into contact with the cathode can 414. Battery 400 shares many of the same elements as those shown in Figures 2A and 2B in relation to Battery 50, and therefore, generally speaking, only the differences are described herein.

[0045] As shown in Figure 7, the battery 400 includes a first electron conductor 466 that is in electronic contact with the cathode can 414 and a second electron conductor 480 that is in electronic contact with the anode cup 418. A spacer 464 is placed between the first electron conductor 466 and the second electron conductor 480. After the battery 400 is exposed to an aqueous solution or bodily fluid, when the electronic insulating material of the spacer 464 dissolves, softens, and / or swells, the second electron conductor 480 can be biased in a direction to engage with the first electron conductor so that the second electron conductor 480 can contact the first electron conductor 466, thereby electronically coupling the cathode can 414 to the anode cup 418. As a result, consumers are protected in a safe state, for example, if the battery 400 is short-circuited or if the battery 400 is swallowed by a person or pet. In the illustrated embodiment, the cathode canister 414 and the first electron conductor are shown as separate components. However, it should be understood that the electron conductor 466 and the cathode canister 414 may form an integrated structure so that the cathode canister 414 itself further functions as an electron conductor 466, effectively providing the electron conductor 466. Therefore, in this embodiment, a separate electron conductor 466 is unnecessary.

[0046] Figure 8 shows a further typical battery 500 with safety mechanisms according to the present disclosure that are designed to protect against tissue damage and / or electrolysis. The battery 500 includes a cathode can 514 and an anode cup 518. A cathode 552 is located in the cathode can 514 and an anode 556 is located in the anode cup 518. The cathode 552 and anode 556 are electronically separated by a separator 560 in the battery 500. The cathode can 514 and anode cup 518 each form a different pole of the battery 500, in this case the cathode can 514 forms the positive pole and the anode cup 518 forms the negative pole. An insulating gasket 562 electronically insulates the cathode can 514 from the anode cup 518, and the insulating gasket 562 seals the battery 500 by preventing any part of the anode cup 518 from coming into contact with the cathode can 514, thereby preventing electrolyte loss. Battery 500 shares many of the same elements as those shown in Figures 2A and 2B in relation to Battery 50 described above; therefore, generally speaking, only the differences are described herein.

[0047] As shown in Figure 8, the battery 500 includes a first spacer 564 and a second spacer 564'. Spacer 564 may constitute a separate portion or a continuous outer layer around the cathode can 514. Similarly, spacer 564' may constitute a continuous layer or a separate portion. Spacers 564, 564' are positioned between the cathode can 514 and anode cups 518 (corresponding to the first and second battery electrodes) and the electron conductor 566. After the battery 500 is exposed to an aqueous solution or body fluid, the dissolution, softening, and / or swelling of the electronic insulating material of spacers 564, 564' can bias the electron conductor 566 in a direction to engage with the cathode can 514 and anode cups 518, thereby electronically coupling the cathode can 514 and anode cups 518. As a result, consumers are protected in a safe state, for example, if the battery 500 is short-circuited or if the battery 500 is swallowed by a person or pet animal.

[0048] Throughout this specification, multiple examples may implement components or structures described as single examples. Structures and functionalities given as separate components in the examples may be implemented as combined structures or components. Similarly, structures and functionalities given as single components may be implemented as separate components. These and other variations, modifications, additions, and improvements are within the scope of the subject matter of this specification.

[0049] Any reference to “one embodiment” or “one embodiment” used herein means that certain elements, features, structures, or characteristics described in relation to that embodiment are included in at least one embodiment. The phrase “in one embodiment” appearing in various places herein does not necessarily refer to the same embodiment.

[0050] Some embodiments described herein use the terms “combined” and / or “connected.” For example, some embodiments use the terms “combined” or “connected” to describe two or more elements that are represented by direct physical or electronic contact. However, the terms “combined” and “connected” may also mean that two or more elements do not have direct physical contact with each other but still cooperate or interact with each other. Embodiments are not limited in this respect.

[0051] As used herein, the terms “equipped,” “containing,” “included,” “having,” “having,” or any other variation thereof are intended to encompass non-exclusive contents. For example, a process, method, article, or apparatus containing a list of elements is not necessarily limited to those elements alone, and may include other elements not expressly listed or specific to such process, method, article, or apparatus. Furthermore, unless expressly stated otherwise, “or” refers to an inclusive “or” rather than an exclusive “or.” For example, element A or B is satisfied by any one of the following: A exists and B does not; A does not exist and B exists; and both A and B exist.

[0052] Furthermore, the use of “one (a)” or “one (an)” is used to describe the elements and components of the embodiments herein. This is done simply for convenience and to give a general meaning to the description. This description and the following claims should be read as including one or at least one, and the singular form also includes the plural form unless it is clear that it means something else.

[0053] Since it is impractical, if not impossible, to describe all possible embodiments, this detailed description should be interpreted as merely an example and not to describe all possible embodiments. Numerous alternative embodiments can be carried out using either the current art or art developed after the filing date of this application.

Claims

1. A battery with a safety mechanism designed to protect against tissue damage and / or electrolysis, A housing comprising a cathode can and an anode cup, and a spacer containing an electronic insulating material, The spacer is provided between the extended portion of the cathode can and the outer wall of the anode cup so as to prevent electronic contact between the cathode can and the anode cup. The spacer is capable of being dissolved, softened, or swollen, and can undergo physical changes in the presence of an aqueous solution such that the resistance of the spacer becomes less than the biasing force of the extended portion, and electronic bonding can occur between the extended portion and the anode cup. Following the physical change, an electronic coupling occurs based on (i) direct physical contact between the extended portion and the anode cup, or (ii) indirect physical contact between the extended portion and the anode cup via one or more further interposed electron-conducting materials placed between the extended portion and the anode cup. A battery in which the extended portion and the cathode can form an integral structure, and the extended portion is biased in a direction to engage with the outer wall of the anode cup.

2. A battery comprising a safety mechanism designed to protect the tissue from damage and / or electrolysis, wherein the electronically conductive material comprises a metal, a metal alloy, a conductive polymer, a conductive composite, or any combination thereof, as described in claim 1.

3. A battery having a safety mechanism to protect the tissue from damage and / or electrolysis according to any one of claims 1 to 2, wherein the electronic insulating material comprises at least one water-soluble material.

4. A battery with a safety mechanism designed to protect the tissue described in any one of claims 1 to 3, wherein the electronic insulating material comprises sugars, polyethers, polyacrylic acid (PAA), polyamide (PA), polyacrylate, polyvinyl alcohol, modified polyvinyl alcohol, acrylate copolymer, polyvinylpyrrolidone, pullulan, gelatin, carboxymethylcellulose (CMC), hydroxypropylmethylcellulose (HPMC), polyethylene oxide, polyethylene glycol, low viscosity grade hydroxypropylcellulose, polysaccharides, natural polymers, modified starch, the copolymers described above, salts thereof, or any combination thereof.

5. A battery with a safety mechanism that protects against tissue damage and / or electrolysis according to any one of claims 1 to 4, wherein the spacer comprises at least one hydrogel.

6. The aforementioned spacer is NaHPO ４ A battery with a safety mechanism designed to protect against tissue damage and / or electrolysis, comprising sodium chloride (NaCl), potassium chloride (KCl), baking soda, sugar, sugar-like substances, citric acid, mixtures thereof, and any combination thereof, according to any one of claims 1 to 5.

7. A battery having a safety mechanism to protect the tissue and / or electrolysis described in any one of claims 1 to 6, wherein the resistance of the electronic insulating material is greater than 0.5 megaohms, greater than 5 megaohms, or greater than 500 megaohms.

8. The battery, with a safety mechanism that protects the tissue from damage and / or electrolysis, is positioned between the protruding portion of the extended portion and the anode cup, as described in any one of claims 1 to 7.

9. A battery having a safety mechanism, wherein the extension portion is provided with a projection, that protects against tissue damage and / or electrolysis according to any one of claims 1 to 8.

10. A battery with a safety mechanism to protect against tissue damage and / or electrolysis, wherein the extended portion comprises a bent portion biased toward engaging with the anode cup, according to any one of claims 1 to 9.

11. A battery with a safety mechanism that further comprises an insulating gasket for electronically insulating the anode cup from the cathode can, wherein the insulating gasket prevents any portion of the anode cup from coming into contact with the cathode can, thereby sealing the battery and preventing electrolyte loss, and protecting against tissue damage and / or electrolysis as described in any one of claims 1 to 10.

12. A battery with a safety mechanism that further includes the spacer, which also functions as an insulating gasket and effectively provides an insulating gasket, electronically separating the cathode can from the anode cup, sealing the battery and preventing electrolyte loss, thereby protecting against tissue damage and / or electrolysis as described in any one of claims 1 to 10.

13. The insulating gasket and the spacer form an integral structure, and the battery has a safety mechanism that protects against tissue damage and / or electrolysis as described in claim 11 or 12.

14. A battery with a safety mechanism that protects the tissue from damage and / or electrolysis according to any one of claims 1 to 13, wherein the extended portion of the cathode can is formed as an extended portion of the side wall of the cathode can.

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