Wafer Alkaline Cell Laminar Seal Design
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Solution Overview
Problem
Conventional alkaline electrochemical cells face challenges in achieving a thin, laminar design suitable for small electronic devices, particularly in maintaining a tight seal and preventing electrolyte leakage, especially as the cell thickness decreases below 6 mm.
Innovation Solution
A wafer alkaline cell design featuring a laminar construction with a tightly bonded sealant and a novel over-wrap design that creates a long leakage path, using a sealing metal precoated on the anode current collector to enhance bonding and prevent electrolyte migration, and employing a staged adhesive seal to ensure durability and resistance to mechanical stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If the cell thickness is reduced to create thin, laminar alkaline cells for small electronic devices, then the cell can be used in smaller devices with thinner battery compartments, but the sealing difficulty increases and electrolyte leakage becomes more likely
Solution Approach 1:
The sealing surfaces are precoated with a sealing metal (such as zinc, cadmium, or tin) before final assembly. This preliminary coating creates a protective layer that enhances bonding and prevents electrolyte leakage, allowing thin cells to maintain reliable seals despite reduced thickness
Solution Approach 2:
The current collectors are constructed as composite structures with a base metal layer and a sealing metal coating layer. This composite design combines the electrical conductivity of the base metal with the sealing properties of the coating, enabling both thin construction and reliable sealing
2Ease of manufacture
If conventional cylindrical cell construction is used, then manufacturing and assembly are well-established, but the cell cannot achieve the thin, laminar design required for small electronic devices
Solution Approach 1:
The cell is divided into separate planar components (anode assembly, cathode assembly, separator) that are manufactured independently and then assembled by bonding. This segmentation allows each component to be optimized for thin construction while maintaining manufacturing simplicity through modular assembly
Solution Approach 2:
The cell construction transitions from three-dimensional cylindrical geometry to two-dimensional laminar geometry. The electrochemical components are arranged in flat, planar layers that can be bonded together, enabling thin cell profiles while using established lamination and bonding manufacturing techniques
3Length of moving object
If the cell is made thinner to reduce size, then the cell fits better in small devices, but the ability to withstand internal pressure and mechanical abuse decreases
Solution Approach 1:
Multiple thin layers (current collectors, active materials, separator, adhesive seals) are bonded together to form a composite laminate structure. This lamination provides mechanical reinforcement, allowing the cell to withstand internal pressure and mechanical abuse despite reduced overall thickness
Solution Approach 2:
The cell uses thin-film current collectors and separator layers that are flexible yet mechanically robust. These thin films are bonded together to create a structure that can deform under pressure without failing, maintaining integrity in thin configurations
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design allows for the creation of thin, durable alkaline cells with reduced electrolyte leakage, capable of withstanding internal pressure and mechanical abuse, while maintaining effective electrical performance across various shapes and sizes, including small, thin formats.
Implementation Method 1
the anode or cathode current collector is precoated with a sealing metal forming an alkaline resistant metal oxide film to improve bonding
Data Source
AI summary
A wafer alkaline cell of a laminar structure is disclosed. The cell has a pair of opposing sides comprising at least the majority of the boundary surface of said cell and defining a short cell dimension therebetween. The cell comprises an anode assembly and a cathode assembly bonded together to form a laminate structure. The cell comprises preferably two separate plastic frames housing the anode and cathode material. The anode current collector may be precoated with a sealing metal forming an alkaline resistant metal oxide film to improve bonding to the frame. The anode assembly has an anode material therein typically comprising zinc and the cathode assembly has a cathode material therein typically comprising manganese dioxide. The cell is durable and preferably rigid, has elongated leak block paths, and resists electrolyte leakage.