Compact multilayer ceramic-to-metal seal structure
AssigneeGeneral Atomics
InventorsM. Harlan Horner, Emilio M. Giraldez
Life of this patent
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Abstract
A compact multilayer ceramic-to-metal seal structure, and method for manufacture, includes a ceramic core with opposed metallic surface layers. Between the ceramic core and each of the metallic surface layers is a transition zone which is made from graded layers of metallic and ceramic powders. These layers have progressively greater concentrations of metallic constituents than ceramic constituents the nearer the layer is to the metallic surface layer. Conversely, within the transition zone, the nearer a layer is to the ceramic core, the greater is its concentration of ceramic constituents. This seal is manufactured by simultaneously sintering a multilayer structure of compressed ceramic and metallic powders.
Claims27
In a battery cell, a compact monolithic hermetic seal for insulating an anode current collector and attached anode from a cathode current collector and attached cathode, said seal comprising a first metallic surface layer attachable to said anode current collector, a second metallic surface layer attachable to said cathode current collector, a ceramic core layer between said first surface layer and said second surface layer, a first transitional zone between said first surface layer and said ceramic core layer, and a second transitional zone between said second surface layer and said ceramic core layer, each said transitional zone being of intermixed metallic and ceramic constituents having a proportionally tapered concentration of said constituents across said zone, said seal confining an electrolyte between said anode, said cathode and said seal to insulate said anode current collector from said cathode current collector.
A compact bipolar battery cell with a separation of less than two tenths of an inch between the anode current collector and the cathode current collector which comprises:
- an anode attached to said anode current collector;
- a cathode attached to said cathode current collector;
- an electrolyte separating said anode from said cathode;
- and
- a hermetic seal for confining said electrolyte between said seal, said anode and said cathode and for insulating said anode current collector from said cathode current collector, said seal comprising a first metallic surface layer attachable to said anode current collector, a second metallic surface layer attachable to said cathode current collector, a ceramic core layer intermediate said first surface layer and said second surface layer, a first transitional zone between said first surface layer and said ceramic core layer, and a second transitional zone between said second surface layer and said ceramic core layer, each said transitional zone being of intermixed metallic and ceramic constituents having a proportionally tapered concentration of said constituents across said zone.
A method for manufacturing a battery cell having a monolithic seal for insulating an anode current collector with attached anode from a cathode current collector with attached cathode which comprises the steps of:
- A) blending a plurality of powders, each of said powders having selected proportions of a metallic constituent and a ceramic oxide constituent;
- B) loading a selected said powder into the recess of a press, said press comprising a plate having a loading surface and formed with an aperture in said loading surface, a platen slidingly positionable in said aperture for distancing said platen from said loading surface to establish said recess, and a plunger insertable into said recess;
- C) compressing said powder in said recess between said platen and said plunger;
- D) withdrawing said platen from said loading surface to reconfigure said recess;
- E) repeating steps B), C) and D) in sequence as desired;
- F) sintering said compressed powders to create said seal having a first metallic surface layer attachable to said anode current collector, a second metallic surface layer attachable to said cathode current collector, a ceramic core layer intermediate said first surface layer and said second surface layer, a first transitional zone between said first surface layer and said ceramic core layer, and a second transitional zone between said second surface layer and said ceramic core layer, each said transitional zone being of intermixed metallic and ceramic constituents having a proportionally tapered concentration of said constituents across said zone;
- and
- G) attaching said first metallic surface layer of said seal to said anode current collector and said second metallic surface layer to said cathode current collector to confine an electrolyte between said seal, said anode and said cathode to create said battery cell.
A method for manufacturing a battery cell having a monolithic seal for insulating an anode current collector with attached anode, from a cathode current collector with attached cathode, which comprises the steps of:
- A) preparing a plurality of flexible tapes, each of said tapes including a powder having selected proportions of a metallic constituent and a metallic oxide constituent;
- B) cutting said flexible tapes into substantially annular shapes;
- C) consolidating said precut flexible tapes to create a multilayer structure;
- D) sintering said consolidated multilayer structure to create said seal, said seal having a first metallic surface layer attachable to said anode current collector, a second metallic surface layer attachable to said cathode current collector, a ceramic core layer intermediate said first surface layer and said second surface layer, a first transitional zone between said first surface layer and said ceramic core layer, and a second transitional zone between said second surface layer and said ceramic core layer, each said transitional zone being of intermixed metallic and ceramic constituents having a proportionally tapered concentration of said constituents across said zone;
- and
- E) attaching said first metallic surface layer of said seal to said anode current collector and said second metallic surface layer to said cathode current collector to confine an electrolyte between said seal, said anode and said cathode to create said battery cell.
Dependencies are inferred from the claim text.