CA1102870A - Mandrel for spirally winding electrochemical cell pack - Google Patents

Abstract

Abstract of the Disclosure A spirally wound element comprising opposite polarity plates and interleaved separator is described, for use in electrochemical cylindrically configured cells. The cell pack has a uniform predetermined cross section irrespective of variation in component thicknesses as long as such thicknesses are within specified tolerances. A mandrel for facilitating the winding of the cell pack has a pair of oppositely disposed, notched lands which extend inwardly from the peripheral surface of the mandrel for receiving leading edges of the cell pack to be wound. The mandrel also has a pair of major edge surfaces extending from the lands about a major portion of the periphery of the mandrel; the edge surfaces are defined by a generally spiralled curvature.

Description

ll~ Z~7~) This application is a divisional of copending Canadian applica-tion serial No. 288,664 which was filed on October 13, 1977 by The Gates Rubber Company.
This invention relates to the production of geometrically uniform spiral cell packs accommodating dimensional variations in components, where at least one of the components is readily compressible and, more particularly, to mandrels used in winding the cell packs.
Various techniques for spirally winding electrochemical cells into a generally cylindrical ("jelly roll") configuration are known, and include the driven mandrel type (e.g., United States Patent No. 3,298,871 to Binder et al), the driven mandrel and idling pressure roll type (e.g., United States Patent No. 1,269,778 to Becker and United States Patent No. 3,839,088 to Hug et al). The use of a single endless belt serpentined about a series of rol-lers, for instance of the general type shown in United States Patent No.
171,346 to Broas, has also been used to spirally wind electrochemical cell packs; a weight tensioning device is attached to one of the rollers to produce a cell pack of uniform mutual stacking pressure between the components.
While the aforementioned types of spiral winders have their bene-fits in particular applications, one disadvantage prevalent with each of the above types is that the resultant cross-sectional geometrical configuration of the cell pack will vary significantly with relatively small variances in component (i.e., plate and separator) thicknesses. The obvious practical problems resulting from these inconsistent geometrical cross sections is that the outside diameter of the "cylindrical" cell pack is oftentimes too large for the cylindrical container in which it is to be stuffed, or alternatively is too loose to snugly fit into such container. As a result, the scrap rate for such spirally wound elements may become unbearably high, or it may become O. .
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necessary to maintain very close tolerance control over incoming components, resulting in increased production costs.
Another important criteria for spiral winder is that it provides for limited differential slip between the plate and separator components dur-ing winding. As the components are being wound upon themselves the outermost components are normally placed in tension, while the inwardly adjacent com-ponent is following a winding curvature defined by a smaller radius than the outermost component and will therefore be put either into compression or re-latively less tension than the outermost component. Particularly where fragile or dimensionally unstable components are being wound, the inability of the components to slip one with respect to another may result in separator stretch-ing or tearing, the separator folding back upon itself, and/or the plates folding back upon themselves. It is known that any of the just described phenomena can lead to premature cell failure due to internal shorting, par-ticularly in rechargeable cells which experience plate growth during cycling.
The aforementioned problems which develop when there is improper relative slip between the components is accentuated when the separators are made of a material which is extremely fragile and difficult to handle, such as nonwoven ultra fine mats of fiber glass or other high heat of wetting material. ~he problem may become particularly critical when employing plates utilizing soft and pliable substrates onto which is affixed a sticky or tacky paste material which may become physically bonded to the separator strips in advance of the point of wind, and therefore preclude relative slip-ping during winding.
It is a primary object of the subject invention to overcome the prior mentioned problems; to provide a wound cell element having a very uni-form cross-sectional geometry even though the components may vary substantially

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in thicknesses; to provide a wound element in which the components are in alignment with respect to each other; to provide a wound element in which the pasted surfaces of the cell plates are not marred, scratched, allowed to crack, or otherwise damaged during winding; to provide a winding process in which the separators and plates are permitted to slip relative to one another during winding while maintaining proper winding pressure and, more particu-larly, to provide an improved mandrel.
Briefly described, according to the present invention, there is provided a generally cylindrical mandrel facilitating the spiral winding of multiple components of flexible strips, comprising:
a pair of oppositely disposed, notched lands which extend inwardly from the peripheral surface of the mandrel for receiving leading edges of the flexible components to be wound, and a pair of major edge surfaces extending from the lands about a major portion of the periphery of the mandrel, the edge surfaces being defined by a smooth curve.
Preferably, the edge surfaces are defined by a generally spiral curvature.
The present invention, and that of above mentioned Canadian ap-plication serial No. 288,664, will be more particularly described in certain of its preferred embodiments by reference to the accompanying drawings, where-in like numerals designate like parts, and in which:
Figure 1 is a perspective view of a portion of the winding appar-atus as it is winding cell components in spiral form;
Figure 2 is a top plan, schematic view of the winding apparatus generally viewed along lines 2-2 of Figure l;
Figure 3 is an enlarged view of the ends of the winding heads, mandrel and cell components in position just prior to winding;

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Figure 4 is a view similar to Figure 3 showing the cell components having been partially wound;
Figure 5 is a side, partial cutaway view of a representative electrode plate which is being wound by the winding apparatus of the inven-tion;
Figure 6, on the second sheet of drawings, is a partial view taken along line 6-6 of Figure 2;
Figure 7 is a side view of a wound subassembly in association with a container shown broken away;
Figure 8 is a horizontal partial cross-sectional view, taken gen-erally along section 8-8 of Figure 7, of the finished wound subassembly of plates and separators produced with the winder of the invention; and Figure 9 is a cross section of the preferred winding mandrel of the invention.
The invention will be described in conjunction with the manufac-ture of spirally wound cell packs ~i.e., subassemblies) of the lead-acid re-chargeable type generally shown in United States Patent No. 3,862,861 to McClelland et al. However, the invention is not so limited and broadly ap-plies to spirally wound cell packs for use in various types of electrochemical cells.
(1) The Cell Subassembly The electrochemical cell subassembly and its components are shown generally at 10 in Figures 7 and 8 and comprise a flexible positive plate 12, a negative plate 14 and interleaved, compressible separator member 16. These components are formed in a jelly-roll (spiral) configuration under a suitable winding tension, and are retained in this mutual compressive relationship by a tail member 18 (shown in Figure 7) which is wrapped circumferentially about ~ z~

the cell subassembly and adheres onto itself with the aid of binder 20 to con-strict the wound element to its generally cylindrical configuration. The tail material is generally of greater strength and much thinner than the adjacent separator 16. The binder or adhesive 20 may be provided by suitable double-backed tape, for instance.
Each of the electrode plates may have the configuration shown in Figure 5, which includes a grid substrate 22, which may be in perforated form, expanded mesh, woven wire screen or other suitable substrate, on which is present a uniform layer 24 of electrochemically active paste such as lead oxide. The paste forms a surface layer on either side of the grid as well as impregnating the interstices 25 in the grid substrate.
The plate also carries a plurality of spaced radially aligned positive current collector tabs 26, 28, 30, 32 and negative tabs 26', 28', 30' and 32'. As will be seen from the wound element of Figure 7, in one em-bodiment employing at least three tabs, the radially innermost positive tab 26, and radially outermost tab 32 protrude axially upwardly beyond the inter-mediate tabs 28J 30. This difference in tab length has been found to be beneficial when welding such tabs to an associated terminal post, such as when employing the method and apparatus disclosed in United States Patent No.
20 3,873,803 to Young et al. In the method of that patent, a lead post leg ~not shown here) is inserted in between tabs 28 and 30, and each of tabs 30 and 32 are positioned adjacent one side of such lead post, and similarly tabs 26 and 28 are positioned adjacent the other side of the lead post. The tabs are then welded to the post using the mold puddling technique taught in that pa-tent. With the outermost tabs 26, 32 extending beyond the inner tabs 28, 30, the ends of all of the tabs in the ready-to-weld position are generally coter-minous, thereby enabling an improved positive unit~ary weld joining all of the " ~Lf.~Z~

tabs and post leg together and producing a weld of reduced internal impedance.
The amount of extension of the outer tabs will be determined by the height of the lead post leg and lateral spacing between tabs.
Alternatively, the tabs may be of generally even height for per-formance of the method and use of the winding apparatus of the invention. It is preferred in this embodiment to employ at least two tabs per plate, three or four being more preferred.
Referring to Figure 8 an important feature of the cell of the in-vention is that the wound element 10 has an extremely uniform cross-sectional geometry. Specifically, the spiral or cylindrical cell pack, as measured along its greatest ~"outside") diameter, or in general, diametrically across any particular "diameter", such as diameter ab, or diameter cd, for instance, has a predetermined dimension (within very small tolerances generally varying less than about plus or minus one percent from the nominal diameter) irres-pective of the individual thickness of the positive and negative plates and separator, as long as such thicknesses are within certain specified tolerances and the lengths of the plates and separators are substantially fixed. In essence, the invention describes a cylindrical cell having a predetermined cross-sectional geometry shape and constant outside diameter ~within the above specified tolerances) even though the individual positive and negative plates taken together with the separators associated with each of the plates, have a combined ~uncompressed) thickness within plus or minus up to about 3 percent of its given nominal design ~uncompressed) thickness.
As will also be appreciated, the foregoing is true only if the separator thickness is capable of being compressed at least as much as the plates are oversized ~compared to design). In comparison, conventional spi-ral cell packs, to Applicants' knowledge, could not be produced having an 37~

outside diameter within plus or minus about one percent of the nominal dia-meter without maintaining very tight control over the combined uncompressed thickness of the positive and negative plates and the two adjacent associated separators to be wound. Achievement of this predetermined cross-sectional geometry stems from the compressibility of the separator element to compensate for variances in component thicknesses, and the manner in which the cell is wound. Hereafter will be described a method for obtaining this desired spiral configuration, which will provide for repeatedly uniform wound elements. An obvious advantage of having a cell pack of uniform dimension is that it may be properly fitted within an outer container (only a portion of which is shown at 34).
As discussed more fully in the aforementioned United States Pa-tent No. 3,862,861, the spirally wound element lO, if ear-marked for use in a lead-acid cell, may be sealed in a suitable acid resistant container 34, which may be made of polypropylene, for instance, and then further stuffed into a metal container (not shown) for shock resistance. Connection of the positive and negative electrode tabs to their appropriate lead posts and connection of the posts to the opposite polarity terminals of the cell may be done in any desired manner. The steps remaining to make the cell ready for use, includ-ing acid addition and formation, are well known to those skilled in the artand do not form a part of the invention herein claimed.
(2) Winding Apparatus Referring to Figures l and 2 of the drawings, the winder mechanism includes dual winding heads 36, 38, a free turning mandrel 40 disposed between the winding heads, a first cell plate feeder 42, a second cell plate feeder 44 and a mechanical drive mechanism 46 linked to each of the juxtaposed 2~

winding heads 36, 38 for retracting the heads away from each other to the po-sition shown in solid lines in Figure 2, or movable toward each other to the position shown in phantom. The winding mechanism is mounted on frame 9, shown schematically throughout Figure 2, with the mechanical drive linkage 46 being mounted along the undersurface of the frame. The winding heads are pivotable about hubs 48, 50. The movement of the winding heads is generally along center line X-X shown in Figures 3 and 4. In this embodiment center line X-X will pivot clockwise as the elements are wound because of the rota-tive movement of the winding heads. Alternatively, the winding heads could move on a straight line normal to the initial plate feed direction if the winding heads were mounted for rectilinear movement. In either case, this center line also pierces the intermediately disposed mandrel 40, about which the cell components are wound.
While it is contemplated that there may be other types of mandrels which may be employed to wind a spiral cell pack according to the invention, it has been found that the particular design shown in horizontal section in Figure 9 is highly preferable since the resulting cell pack is of the desired predetermined dimension, no foldbacks or stress points are produced during wind, and the occurrence of "no-winds" is virtually eliminated. Referring to 20 that figure, the mandrel 40 consists of a generally circular base shaft 150, mountable for free turning, and an upper winding portion comprised of a pair of inwardly angled notched lands 39, 41, which receive the leading edges of the cell pack to be wound, and from which project juxtaposed major edge sur-faces 152, 154, defined by a generally spiralled curvature. The spiral starts at the inward extent of one land and continues until terminating approximately at the outer edge of the opposite land. The depth of the notches of the lands may be equal to from about one-half ~as shown) up to the full combined ~2~i7Q

equivalent thickness of the appropriate plate and its adjacent separator layers.
The winding heads each comprise upper plate 52, 52' and lower plate 53, 53' mounted to the hubs. Mounted between the upper and lower plates and at the winding end of each of the heads is a pair of free turning pressure rolls 54, 56 and 58, 60 laterally straddling the winding head center line.
There is also disposed between the upper and lower plates tension roller 62, 64, and other free turning rollers (e.g., 59) disposed about the perimeter of the winding heads, about which along with the pressure rolls 54, 56 and 58, 60 is trained a flexible endless belt driving surface 66, 68. The belts are driven with drive rollers (shown hidden at 48', 50' coaxially mounted with hubs 48, 50) at least one (and preferably both) of which is driven, and the desired tension on the belt is obtained by adjusting the position of the tension roller 62, 64 with the spring biased adjusting mechanism 74, 75 attached to the upper plates of the winding heads. The belts are preferably essentially nonextensible. Pinch rolls 70, 72 are employed to ensure positive driving of the belt without slippage.
Each of the pairs of pressure rollers 54, 56 and 58, 60 are offset with respect to one another and the lines connecting each o the roller pair centers are non-parallel with respect to the direction of plate feed, as shown particularly in Figures 3 and 4, the importance of which will be des-cribed more fully hereafter.
The winding heads 36, 38 may be retracted relative to one another in any desired fashion, however, to produce a wound cell pack element having the preferred predetermined geometrical cross section as shown in Figure 8, it is necessary to provide a retracting mechanism which will withdraw the winding heads away from each other during winding at a predetermined _g _ ~i ;2;~7~
programmed rate relative to the rate at which the winding belts are driven.
One such mechanism is shown generally at 46, and includes cam surface 76, whose shape will be determined by the desired geometrical cross section of the cell pack to be wound, and a linkage which translates the cam shape directly into a corresponding retractive movement of the winding heads by rods 82, 84 pin connected (not shown) to the lower plates 53, 53' of the winding heads.
This linkage includes a cam follower 78 pivotable about point 81. The cam follower is connected to link 80 pivotable about center 86 (which is prefer-ably adjustably locatable), the link being connected to one end of an adjust-able rod 88 connected to a fixedly mounted piston cylinder 90 for movement as shown by the arrows in Figure 2. Bell crank 92, pivotal about pivot 94, translates the motion of rod 88 through the pin connection 96. The rocking motion of the belt crank is converted to linear reciprocal motion of the pinned rods 82, 84 which determine the respective movement of the winding heads.
The rotational speed of the winding belts 66,`68 is directly pro-portional to the linear speeds of the connecting rods 82, 84. This is accom-plished in the preferred mode by a positive drive belt 138 (partially shown) connecting cam 76, drive roller 48' and drive roller 50' along the under-surface of the frame 9 for synchronous rotation.
The plate and separator feeders 42, 44 include bifurcated plate guides 98, 100 which, respectively, straddle each of the negative 14 and positive 12 electrode plates. Each of the halves of the bifurcated guides may be spread apart to load and unload the plates. Each of the guides are slidably movable toward and away from the winding area on tracks 102, 104 and 106, 108. ~ach of the guides 42, 44 are pivotal about a point (not shown) near their trailing end, so that the guides automatically pivot through an angle similar to each of the winding heads 36, 38 to insure that the ~ z~
components are fed substantially tangentially to the winding cell pack. The component feed angle with respect to axis X-X should be 90 (tangential) or less to prevent component stretching.
As an additional alternative one or both of the halves of each of the guides may preferably act as a forwardly ~and retractably rearwardly) movable tuck blade, movable to the position shown in phantom at 98' of figure 2, to assist in picking up the separator and delivering it to the winding area while protecting the associated plate from being misaligned.
The separator material 16 is initially positioned loosely within a set of guides, a portion of which are shown at 110-117 ~Figure 2 only) which hold the separator generally transversely of the direction of plate feed, as shown in phantom at 118, 119. Further separator guide means are provided by lead-in curves 120-123, overhanging ledges e.g., 158, 160 of the plate guides or alternatively the upstanding straddling guides 130, 132 ~Figure 1 only), which come into play as the plates are fed into the winding area.
~ 3) Method of Winding Preparatory to winding, the machine is at rest and the winding heads 38 and 36 are in their retracted position as shown in solid lines in Figure 2. Air cylinder 90 has been actuated to maintain rod 88 at its pro-per throw to insure that the winding heads are fully retracted and out of theway of the incoming plate feeding mechanism.
Initially the positive plate feeder 42 and plate leading edge 43 are to the right of the plane defined by the initial position of the separator along line 119. Similarly, the negative plate feeder 44 is retracted to the left of line 118. Separator material in the form of single or multiple layers is now inserted between guides 110-117 and disposed transversely to the plate feeding mechanism, along planes 118, 119. As will be noted, tail 18, which has been cut to length, is attached to one of the separators 16 and includes double-backed adhesive 20 for adhering to itself once the components are fully wound.
In the next step, each of the plate feeding mechanisms 42, 44 are advanced along their respective tracks toward the winding area, and in so doing the leading edges 43 and 45 of the plates (or the forwardly extending tuck blades 98') which are less pliant than the separator material, pick up their respective separators 16 and carry them along with the plates without relative slipping. Plate feeder 42 is directed to one side (i.e., the top side) of the mandrel 40 while the other plate is directed toward the opposite side of the mandrel 40. The leading edges 43, 45 of the plates are advanced approximately to a position even with the far end of the mandrel and opposite the receptive grooves 39, 41 formed therein. Up to this point, the plates are physically separated from the adjacent carried separators, except for point contact at ends 43 and 45, and no contact has been made with the mandrel or winding belts.
The winding heads 38 and 36 are now locked into position prepara-tory to winding, as shown in Figure 3. This is accomplished by rotation of cam 76 clockwise until point 77 on the surface of the cam is opposite roller 79 of cam follower 78. Air cylinder 90 is actuated so that rod 88 moves rightwardly, cam follower 78 engages the cam at point 77, and non-moving belt surfaces 66 and 68 of the winding heads engage the separators and sandwiched plates and press them against the mandrel.
With the winding heads locked into place as shown in Figure 3, the winding belts in the area intermediate each of rollers 54, 56 and 58, 60 take on a significant curvature due to their flexibility and compression against the sandwiched plates and separators. The amount of curvature is regulated ~ ~ ~ 2 ~-f~

by the tension rollers 62, 64 and associated tensioning devices 74~ 75. This curvature of the belts in turn makes the leading edge of the plates 43 and 45 take an arcuate set. This initial arcuate set is believed to be critical during initiation of the winding process to insure that the desired spiral configuration is obtained. The slots or lands 39, 41 in the S-shaped mandrel, assist in formation of this arcuate set and provide a smooth continuous sur-face flush with the mandrel curvature for improved spiral mating of the sand-wiched plates with one another during winding start up.
The plates and separators are being fed tangentially to the man-drel without coming into contact with one another substantially until thepoint of contact tangentially with the mandrel, and then with winds of the cell pack as winding proceeds.
With the leading edge of the cell plates and adjacently disposed separator formed about the mandrel as shown in Figure 3, the winding belts 66 and 68 are then driven by actuation of drive rollers 48' and 50' (in turn driven by belt 138), in synchronization with rotation of cam 76. As the winding belts are driven, the mechanical linkage operatively connected to cam 76 causes the winding heads to retract essentially along the variable center line X-X. The components spirally wind upon each other since the plates and separators are freely and loosely disposed within their guides and the guides are progressively pivoted away from the mandrel so that the com-ponents are fed substantially in a straight line tangential to the winding cell pack. The predetermined programmed rate of withdrawal of the winding heads together with the desired tensioning maintained by the belt driving surfaces and directly supported by the rollers causes the cell pack to be spirally wound in predetermined fashion so that its final outside "diameter", or any other diameter, for instance ab and cd shown in Figure 8, are of ~ ~i2~

predetermined dimension. This dimensioning will be maintained since thewinder automatically compensates for variations in component thicknesses by compressing the separator the necessary amount throughout the wind. Further-more, this programmed geometrical winding automatically lines up the positive and negative tabs, as shown in Figures 4 and 8.
It will be noted that throughout the period of wind the driving belts 66 and 68 are making total vertical contact with the cell and touch the outer separator layers and not the sticky or tacky electrode plates. The belts are at least partially deflected throughout the wind, producing a curved portion between rollers 54, 56 and 58, 60 and therefore offer a large contact area for winding. Since there are two winding heads, each preferably driven, each plate is essentially driven independently (although synchronously) of the other plate, and a very balanced winding system is provided in which the components are tensioned uniformly during the wind yet permitted limited differential slipping.
An important feature which ensures obtaining a cell pack of con-trolled diameter is the positioning of the roller pairs 54, 56 and 58, 60.
During the entire winding operation at least one or both of the individual rollers of each of these roller pairs apply direct pressure (through the interposed belt) against the separators and plates being wound, permitting accurate mechanical control of plate spacing and final cell diameter.
At the end of the wind cam 76 has moved clockwise~from point 77 to point 75, at which time the winding heads 36, 38 are stationary and the plates and separators have been fully wound up in spiral form with the tail member 18 fully circumscribing the cell and self-adhered to itself. The tail 18 acts as a retainer for the wound element, preventing unwinding. In the final step, the winding heads are retracted still further to the initial position shown in solid lines in Figure 2, with the aid of air cylinder 90. The spirallywound element is then ejected or removed from the mandrel upwardly ~a con-ventional ejection mechanism may be employed, or it may be done manually) and the machine, upon retracting the plate guide elements 42 and 44, is ready to start the next winding cycle.
The wound element, as shown in Figure 8, is extremely uniform with essentially equal spacing between the plates throughout the radial ex-tent of the spiral. The mutual stacking compression between the elements may vary somewhat, according to the thicknesses of the components wound, al-though the tension will be maintained within a desired range, particularly with the aid of tension rollers 62 and 64 of the winding heads. The finished cell, as aforementioned, will have a cross section of a predetermined, pro-grammed geometry since the winder will compensate for differences in component thicknesses. Moreover, since the plates and separators do not actually come into interfacial contact until the point of wind is encountered, the compon-ents will be permitted to slip relative to one another as the spiral is formed, and thus overcome the proble~s characteristic of many prior art winders.
(4) Modifications of the Invention It will be understood that the invention is capable of a variety of modifications and variations which will become apparent to those skilled in the art upon a reading of the specification, such modifications intended to be part of the invention as defined in the appended claims.

Claims (8)

THE EMBODIMENTS OF THE INVENTION IN WHICH AN EXCLUSIVE
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:

1. A generally cylindrical mandrel for facilitating the spiral winding of an electrochemical cell pack comprising electrode plates and inter-leaved separators, comprising: a pair of oppositely disposed, notched lands which extend inwardly from the peripheral surface of the mandrel for receiv-ing leading edges of the cell pack to be wound, and a pair of major edge surfaces extending from the lands about a major portion of the periphery of the mandrel, the edge surfaces being defined by a generally spiralled cur-vature.

2. The mandrel of claim 1 wherein the mandrel is generally S-shaped.

3. The mandrel of claim 1 wherein said spiralled edge surfaces each commences at the inward extent of one notched land and continues until ter-minating generally at the intersection of the other notched land and the periphery of the mandrel.

4. The mandrel of claim 1 wherein the notched lands are defined by a surface which forms an angle with respect to a radial line drawn from the center of the mandrel to the notched land.

5. A generally cylindrical mandrel facilitating the spiral winding of multiple components of flexible strips, comprising:
a pair of oppositely disposed, notched lands which extend in-wardly from the peripheral surface of the mandrel for receiving leading edges of the flexible components to be wound, and a pair of major edge surfaces ex-tending from the lands about a major portion of the periphery of the mandrel, the edge surfaces being defined by a smooth curve.

6. The mandrel of claim 5 wherein said curve is generally a spiral.

7. The mandrel of claim 5 wherein said mandrel cross section is generally S-shaped.

8. The mandrel of claim 6 wherein the respective spiral edge sur-faces commence at the inward extent of one of the inwardly notched lands and continue until terminating generally at the intersection of the other in-wardly notched land and the periphery of the mandrel.