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US3156749A - Impact molding of galvanic cell cathodes - Google Patents

Impact molding of galvanic cell cathodes Download PDF

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US3156749A
US3156749A US145325A US14532561A US3156749A US 3156749 A US3156749 A US 3156749A US 145325 A US145325 A US 145325A US 14532561 A US14532561 A US 14532561A US 3156749 A US3156749 A US 3156749A
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Prior art keywords
punch
cathode
container
cathodic
mix
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US145325A
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Lee C Hosfield
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Union Carbide Corp
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Union Carbide Corp
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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M6/00—Primary cells; Manufacture thereof
    • H01M6/04—Cells with aqueous electrolyte
    • H01M6/06—Dry cells, i.e. cells wherein the electrolyte is rendered non-fluid
    • H01M6/08—Dry cells, i.e. cells wherein the electrolyte is rendered non-fluid with cup-shaped electrodes
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S425/00—Plastic article or earthenware shaping or treating: apparatus
    • Y10S425/812—Venting

Definitions

  • a cylinder of mix is provided in juxtaposition with the inside of the cell container. This cylinder serves as the cathode or current collector in the cell reaction and must be compressed tightly to minimize internal resistance.
  • cathodes are currently being produced by one of two methods.
  • the cathodes in alkaline cells are conventionally provided by compression molding of a preform of cathodic mix comprising manganese dioxide and graphite in the cell container, followed by a despruing or removal of the compressed mix in the center of the preform.
  • This method is not completely satisfactory due to the rapid wear which is encountered on the high pressure hydraulic equipment that it used to apply the pressure.
  • the tools which are employed to perform the de-spruing operation are expensive and wear rapidly on the somewhat abrasive cathodic mix.
  • the cathode or current collector in the Leclanch cell of the type described is composed of a cylinder of graphite and wax which is in juxtaposition with the inside of a paper spiral wound tube which forms the cell jacket.
  • the common method now in use to form such cathodes consists of injection molding them in large presses which are provided with necessary heating and cooling cycles. It will be appreciated that the time cycle of such equipment is controlled by the fact that the formed cathode must be allowed to cool to a temperature at which it will not distort or sag when it is removed from the press.
  • the principal object of the invention is to provide a process for forming cylindrical cathodes which avoid the above disadvantages of the prior art.
  • Another object of the subject invention is to provide a process for forming cylindrical cathodes quickly and efficiently and which may be carried out in simplified equipment.
  • the objects of the invention are accom plished by impact molding of a cylindrical cathode mix in place within a cylindrical galvanic cell container. utilizing a fluted molding punch as the molding force.
  • the process of the invention con1 prises driving a punch into a cell container into which more cathodic mix than is required to form the cathode of the particular cell, has been deposited.
  • the excess cathodic mix is forced out of the cell container by means of a plurality of flutes on the side of the punch. In the preferred embodiment at least three flutes should be provided, and best results have been obtained with six flutes.
  • a cell container 10 is shown in position in a cavity 11 in a base 12 of a punch press 14.
  • the cell container 10 resides on an ejector member 16 which is used to remove the container 10 from the cavity 11 after the cathode 18 is formed.
  • a punch 20 which is provided with a plurality of flutes 21 and which is part of the upper por tion 22 of the punch press 14 is driven into a partially precompressed cathodic mix or into a plurality of pellets made from the cathodic mix the punch '20 having a diameter smaller than the inside diameter of the cell container 10.
  • the density of the mix or pellets should be at least 2.2 grams per cubic centimeters. This action forms the cathode 18 into the desired shape which is controlled by the space defined by the fluted punch 20 and the walls of the punch cavity 11. As can be seen from the drawing, the excess cathodic mix will be ejected from the cavity 11 by means of the flutes 21 which extend above the cavity 11. A stripper ring 24 retains the cathode 18 in place while the punch 20 is being withdrawn.
  • a force rotating eccentric cam 26 is provided which will rotate the punch from about 5 to 30, 15 being preferred, to break the adhesive force between the punch 20 and the cathode 18, before the punch 20 is withdrawn.
  • the rotation takes place when the upper portion 22 of the punch press 14 starts the upstroke and while the punch 20 is held in the down position by a spring 28 until the slack is taken up in a linkage 30.
  • This rotation of the punch 20 also irons over the rough places on the inner wall of the cathode 18 along where the excess cathodic mix was ejected by means of the flutes 21.
  • G size alkalinemanganese dioxide-zinc cells were made with cathodes formed by the impact molding process disclosed.
  • a G size cell is defined in circular C 466 of the National Bureau of Standards of the United States Department of Commerce. The cells so produced gave 48 cycles to .9 volt on the 1.125 ohm 4 hour discharge, 500 milliamp, 10 hour charge cycle. Cells of the identical size with cathodes producedby the conventional molding technique described, gave only 43 cycles when subjected to the same test.
  • Leclanch cathodes formed by impact molding also compared favorably with the conventionally prepared Leclanch cathodes when compared on a resistance basis.
  • the cathodes were immersed in mercury and the resistance was read through the cap on bridge.
  • the resistance values of the cathodes'of the invention varied from .060 to .110 ohm per linear inch while the range for the injection molded prior art cathodes was from .095 to .126 ohm per linear inch.
  • the lower resistance for the cathodes of the invention is indicative of the high density which is achieved by the process of the invention.
  • the process and apparatus of the invention has proved successful in the control of the amount of material in the cathode formed by the molding operation.
  • the amount of cathodic mix added to the cell container was varied between 26 and 34 grams.
  • the weight of the molded cathode after being formed by the fluted punch varied only from 24.33 to 26.04 grams, thus demonstrating that a desired final cathode weight can be obtained even though a substantial vari- I bottom of said cell container; driving a cylindrical punch, smaller in diameter than the inside diameter of said cell container and provided with a plurality of flutes for expelling said excess of said cathodic mix from said container, into said cathodic mix, removing said excess of said cathodic mix through said flutes while the remainder of said cathodic mix is molded into a cathode between said punch and the inner walls of said cell container, rotating said punch a slight amount prior to withdrawal from said container whereby said excess of said cathodic mix in said flutes is sheared and severed off from said formed cathode; and then removing said punch from said cell container thus forming a finished cathode-container structure.
  • An apparatus suitable for impact molding a cylindrical cathode in place in a cylindrical container containing an excess of cathodic mix therein which comprises, a punch press, said punch press comprising a movable upper portion having a cylindrical punch provided with a plurality of flutes for expelling said excess of said cathodic mix from said cylindrical container, a stationary lower portion provided with a cavity for receiving said cylindrical container containing said excess of cathodic mix which is in line with said fluted punch, a cam having an oblique slot for controlling the rotation of said fluted punch, resilient means urging said fluted punch downwardly, means for moving said fluted punch in and out of said cavity, said fiutes of said punch extending above said cavity when said punch is within said cavity, and a cam pin rigidly attached to said movable upper portion of said press which rides in said oblique slot of said cam, whereby said punch rotates from about 5 to about prior to the initial withdrawal of said punch from said cavity and whereby said excess of said cathodic mix in said flutes

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Electrochemistry (AREA)
  • General Chemical & Material Sciences (AREA)
  • Battery Electrode And Active Subsutance (AREA)

Description

Nov. 10, 1964 L. c. HOSFIELD IMPACT MOLDING 0F GALVANIC CELL CATHODES Filed Oct. 16, 1961 INVENTOR.
LEE C. HOSFIELD ATTORNL/Y United States Patent 3,156,749 IMPACT MOLDING 0F GALVANIC CELL CATHODES Lee C. Hosfield, Sarasota, Fla., assignor to Union Carbide Corporation, a corporation of New York Filed Oct. 16, 1961, Ser. No. 145,325 3 Claims. (Cl. 264-161) This invention relates to an improved process for molding cathodes for use in electrochemical cells and to apparatus suitable for performing such a process.
In certain type cylindrical galvanic cells such as alkaline-manganese dioxide-zinc cells and Leclanch cells of the type which are referred to as inside out cells (US. Patent 2,605,299, I. P. Teas, July 29, 1952), a cylinder of mix is provided in juxtaposition with the inside of the cell container. This cylinder serves as the cathode or current collector in the cell reaction and must be compressed tightly to minimize internal resistance.
These type cathodes are currently being produced by one of two methods. The cathodes in alkaline cells are conventionally provided by compression molding of a preform of cathodic mix comprising manganese dioxide and graphite in the cell container, followed by a despruing or removal of the compressed mix in the center of the preform. This method is not completely satisfactory due to the rapid wear which is encountered on the high pressure hydraulic equipment that it used to apply the pressure. In addition, the tools which are employed to perform the de-spruing operation are expensive and wear rapidly on the somewhat abrasive cathodic mix.
The cathode or current collector in the Leclanch cell of the type described is composed of a cylinder of graphite and wax which is in juxtaposition with the inside of a paper spiral wound tube which forms the cell jacket. The common method now in use to form such cathodes consists of injection molding them in large presses which are provided with necessary heating and cooling cycles. It will be appreciated that the time cycle of such equipment is controlled by the fact that the formed cathode must be allowed to cool to a temperature at which it will not distort or sag when it is removed from the press.
The principal object of the invention is to provide a process for forming cylindrical cathodes which avoid the above disadvantages of the prior art.
Another object of the subject invention is to provide a process for forming cylindrical cathodes quickly and efficiently and which may be carried out in simplified equipment.
Broadly stated, the objects of the invention are accom plished by impact molding of a cylindrical cathode mix in place within a cylindrical galvanic cell container. utilizing a fluted molding punch as the molding force.
The invention will be more readily understood by reference to the accompanying drawing wherein the single figure is a front elevation partially in section, of a punch 7 press suitable for carrying out the process of the invention, and which shows a fluted punch within a cylindrical cell container in the process of forming a cathode.
More specifically, the process of the invention con1 prises driving a punch into a cell container into which more cathodic mix than is required to form the cathode of the particular cell, has been deposited. The excess cathodic mix is forced out of the cell container by means of a plurality of flutes on the side of the punch. In the preferred embodiment at least three flutes should be provided, and best results have been obtained with six flutes.
After the expulsion of the excess cathodic mix, and prior.
3,156,749 Patented Nov. 10, 1964 punch also smoothes over the inner surface of the molded cathode.
Referring now to the drawing, a cell container 10 is shown in position in a cavity 11 in a base 12 of a punch press 14. The cell container 10 resides on an ejector member 16 which is used to remove the container 10 from the cavity 11 after the cathode 18 is formed. In the process of the invention, a punch 20 which is provided with a plurality of flutes 21 and which is part of the upper por tion 22 of the punch press 14 is driven into a partially precompressed cathodic mix or into a plurality of pellets made from the cathodic mix the punch '20 having a diameter smaller than the inside diameter of the cell container 10. In order to insure against poor cathode molding due to entrapment of air in the cathode, the density of the mix or pellets should be at least 2.2 grams per cubic centimeters. This action forms the cathode 18 into the desired shape which is controlled by the space defined by the fluted punch 20 and the walls of the punch cavity 11. As can be seen from the drawing, the excess cathodic mix will be ejected from the cavity 11 by means of the flutes 21 which extend above the cavity 11. A stripper ring 24 retains the cathode 18 in place while the punch 20 is being withdrawn. In the preferred embodiment a force rotating eccentric cam 26 is provided which will rotate the punch from about 5 to 30, 15 being preferred, to break the adhesive force between the punch 20 and the cathode 18, before the punch 20 is withdrawn. The rotation takes place when the upper portion 22 of the punch press 14 starts the upstroke and while the punch 20 is held in the down position by a spring 28 until the slack is taken up in a linkage 30. This rotation of the punch 20 also irons over the rough places on the inner wall of the cathode 18 along where the excess cathodic mix was ejected by means of the flutes 21.
As an example of the invention, G size alkalinemanganese dioxide-zinc cells were made with cathodes formed by the impact molding process disclosed. A G size cell is defined in circular C 466 of the National Bureau of Standards of the United States Department of Commerce. The cells so produced gave 48 cycles to .9 volt on the 1.125 ohm 4 hour discharge, 500 milliamp, 10 hour charge cycle. Cells of the identical size with cathodes producedby the conventional molding technique described, gave only 43 cycles when subjected to the same test.
Leclanch cathodes formed by impact molding also compared favorably with the conventionally prepared Leclanch cathodes when compared on a resistance basis. The cathodes were immersed in mercury and the resistance was read through the cap on bridge. The resistance values of the cathodes'of the invention varied from .060 to .110 ohm per linear inch while the range for the injection molded prior art cathodes was from .095 to .126 ohm per linear inch. The lower resistance for the cathodes of the invention is indicative of the high density which is achieved by the process of the invention.
The process and apparatus of the invention has proved successful in the control of the amount of material in the cathode formed by the molding operation. In a trial of 49, /2 D size alkaline cells, the amount of cathodic mix added to the cell container was varied between 26 and 34 grams. The weight of the molded cathode after being formed by the fluted punch varied only from 24.33 to 26.04 grams, thus demonstrating that a desired final cathode weight can be obtained even though a substantial vari- I bottom of said cell container; driving a cylindrical punch, smaller in diameter than the inside diameter of said cell container and provided with a plurality of flutes for expelling said excess of said cathodic mix from said container, into said cathodic mix, removing said excess of said cathodic mix through said flutes while the remainder of said cathodic mix is molded into a cathode between said punch and the inner walls of said cell container, rotating said punch a slight amount prior to withdrawal from said container whereby said excess of said cathodic mix in said flutes is sheared and severed off from said formed cathode; and then removing said punch from said cell container thus forming a finished cathode-container structure.
2. The process of claim 1 wherein said punch is rotated between approximately 5 and 30.
3. An apparatus suitable for impact molding a cylindrical cathode in place in a cylindrical container containing an excess of cathodic mix therein, which comprises, a punch press, said punch press comprising a movable upper portion having a cylindrical punch provided with a plurality of flutes for expelling said excess of said cathodic mix from said cylindrical container, a stationary lower portion provided with a cavity for receiving said cylindrical container containing said excess of cathodic mix which is in line with said fluted punch, a cam having an oblique slot for controlling the rotation of said fluted punch, resilient means urging said fluted punch downwardly, means for moving said fluted punch in and out of said cavity, said fiutes of said punch extending above said cavity when said punch is within said cavity, and a cam pin rigidly attached to said movable upper portion of said press which rides in said oblique slot of said cam, whereby said punch rotates from about 5 to about prior to the initial withdrawal of said punch from said cavity and whereby said excess of said cathodic mix in said flutes is sheared and severed off from said formed cathodecontainer structure.
References Cited in the file of this patent UNITED STATES PATENTS 1,195,118 Weida Aug. 15, 1916 1,412,962 Perrault et al Apr. 18, 1922 1,585,643 Bello May 25, 1926 2,027,483 Keller Jan. 14, 1936 2,040,674 Severance et al. May 12, 1936 2,359,674 Pollods Oct. 3, 1944 2,561,735 Haller July 24, 1951 2,659,132 Leontes et al. Nov. 17, 1953 2,767,438 Pingel Oct. 23, 1956 2,987,775 Albrecht et a1 June 13, 1961 3,053,713 Juras Sept. 11, 1962 FOREIGN PATENTS 505,815 Italy Dec. 18, 1954

Claims (1)

1. A PROCESS FOR IMPACT MOLDING A CYLINDRICAL CATHODE IN PLACE IN A GALVANIC CELLCONTAINER WHICH COMPRISES THE STEPS OF DISPENSING AN EXCESS FO CATHODIC MIX INTO THE BOTTOM OF SAID CELL CONTAINER; DRIVING ACYLINDRICAL PUNCH, SMALLER IN DIAMETER THAN THE INSIDE DIAMETER OF SAID CELL CONTAINER AND PROVIDED WITH A PLURALITY OF FLUTES FOR EXPELLING SAID EXCESS OF SAID CATHODIC MIX FROMSAID CONTAINER, INTO SAID CATHODIC MIX, REMOVING SAID EXCESS OF SAID CATHODIC MIX THROUGH SAID FLUTES WHILE THE REMAINDER OF SAID CATHODIC MIS IS MOLDED INTO A CATHODE BETWEEN SAID PUNCH AND THE INNER WALLS OF SAID CELL CONTAINER, ROTATING SAID PUNCH A SLIGHT AMOUNT PRIOR TO WITHDRAWAL FROM SAID CONTAINER WHEREBY SAID EXCESS OF SAID CATHODIC MIX IN SAID FLUTES IS SHEARED AND SEVERED OFF FROM SAID FORMED CATHODE; AND THEN REMOVING SAID PUNCH FROM SAID CELL CONTAINER THUS FORMING A FINISHED CATHODE-CONTAINER STRUCTURE.
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Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3321679A (en) * 1962-08-24 1967-05-23 Messrs Frako Kondensatoren Und Rolled foil capacitor having hollow lug terminal with connecting pin therefor
US3377662A (en) * 1965-04-20 1968-04-16 Bridgestone Tire Co Ltd Metal mold having vent plug means for shaping a plastic article and vulcanizing a rubber article
US3384922A (en) * 1964-11-25 1968-05-28 Per Oystein Winsnes Arrangement for the production of molded objects of fiber material, wood chips or other materials
US3577842A (en) * 1968-07-04 1971-05-11 Matsushita Electric Ind Co Ltd Apparatus for compression molding a powder within a container
US4197064A (en) * 1973-08-27 1980-04-08 Donald Macmillan & Son, Inc. Tire retreading bladder
US5447809A (en) * 1984-08-21 1995-09-05 Rayovac Corporation Alkaline primary battery containing coated current collector
US5814419A (en) * 1995-09-01 1998-09-29 Rayovac Corporation Alkaline manganese dioxide electrochemical cell having coated can treated with sodium silicate
US6153330A (en) * 1995-09-01 2000-11-28 Rayovac Corporation Alkaline manganese dioxide electrochemical cell having coated can treated with silicon compounds

Citations (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1195118A (en) * 1916-08-15 Pbocess of making habd-bubbeb abticles
US1412962A (en) * 1921-02-08 1922-04-18 Hood Rubber Co Inc Process of and apparatus for making battery jars
US1585643A (en) * 1924-12-10 1926-05-25 Bello Byfield Corp Manufacture of containers
US2027483A (en) * 1928-06-07 1936-01-14 Richardson Co Method of making composite molded products
US2040674A (en) * 1929-09-11 1936-05-12 Gen Electric Contact pin for vacuum tubes and method of molding
US2359674A (en) * 1943-02-26 1944-10-03 Maguire Ind Inc Press
US2561735A (en) * 1949-07-21 1951-07-24 Haller John Machine for molding helical gears
US2659132A (en) * 1950-08-16 1953-11-17 Dow Chemical Co Composite alloy
US2767438A (en) * 1952-04-14 1956-10-23 Borg Warner Method and apparatus for making torque-transmitting elements
US2987775A (en) * 1957-07-10 1961-06-13 Ransom C Albrecht Method of forming plastic containers
US3053713A (en) * 1958-01-13 1962-09-11 Union Carbide Corp Plastic articles reinforced with preformed precompressed metal fiber elements

Patent Citations (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1195118A (en) * 1916-08-15 Pbocess of making habd-bubbeb abticles
US1412962A (en) * 1921-02-08 1922-04-18 Hood Rubber Co Inc Process of and apparatus for making battery jars
US1585643A (en) * 1924-12-10 1926-05-25 Bello Byfield Corp Manufacture of containers
US2027483A (en) * 1928-06-07 1936-01-14 Richardson Co Method of making composite molded products
US2040674A (en) * 1929-09-11 1936-05-12 Gen Electric Contact pin for vacuum tubes and method of molding
US2359674A (en) * 1943-02-26 1944-10-03 Maguire Ind Inc Press
US2561735A (en) * 1949-07-21 1951-07-24 Haller John Machine for molding helical gears
US2659132A (en) * 1950-08-16 1953-11-17 Dow Chemical Co Composite alloy
US2767438A (en) * 1952-04-14 1956-10-23 Borg Warner Method and apparatus for making torque-transmitting elements
US2987775A (en) * 1957-07-10 1961-06-13 Ransom C Albrecht Method of forming plastic containers
US3053713A (en) * 1958-01-13 1962-09-11 Union Carbide Corp Plastic articles reinforced with preformed precompressed metal fiber elements

Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3321679A (en) * 1962-08-24 1967-05-23 Messrs Frako Kondensatoren Und Rolled foil capacitor having hollow lug terminal with connecting pin therefor
US3384922A (en) * 1964-11-25 1968-05-28 Per Oystein Winsnes Arrangement for the production of molded objects of fiber material, wood chips or other materials
US3377662A (en) * 1965-04-20 1968-04-16 Bridgestone Tire Co Ltd Metal mold having vent plug means for shaping a plastic article and vulcanizing a rubber article
US3577842A (en) * 1968-07-04 1971-05-11 Matsushita Electric Ind Co Ltd Apparatus for compression molding a powder within a container
US4197064A (en) * 1973-08-27 1980-04-08 Donald Macmillan & Son, Inc. Tire retreading bladder
US5447809A (en) * 1984-08-21 1995-09-05 Rayovac Corporation Alkaline primary battery containing coated current collector
US5814419A (en) * 1995-09-01 1998-09-29 Rayovac Corporation Alkaline manganese dioxide electrochemical cell having coated can treated with sodium silicate
US6153330A (en) * 1995-09-01 2000-11-28 Rayovac Corporation Alkaline manganese dioxide electrochemical cell having coated can treated with silicon compounds

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