Battery having fiber electrodes

A battery, comprising:

• a plurality of fiber anodes, each of the fiber anodes comprising
• an anode fiber, and
• a layer of an anode active material overlying the anode fiber;
• a plurality of fiber cathodes bundled with the fiber anodes, each of the fiber cathodes comprising
• a cathode fiber, and
• a layer of a cathode active material overlying the cathode fiber;
• an electrically nonconducting separator layer between the fiber anodes and the fiber cathodes;
• an electrolyte between the fiber anodes and the fiber cathodes;
• a tubular compliant lateral casing laterally surrounding the fiber anodes, the fiber cathodes, the separator, and the electrolyte;
• a protective housing overlying the lateral casing;
• a compliant end plate sealed to the lateral casing at each end thereof,
• an end of each anode fiber extending out of a first end plate at a first end of the battery, and
• an end of each cathode fiber extending out of a second end plate at a second end of the battery;
• and
• a metallic collector plate overlying the compliant end plate at each end of the battery.

A method for preparing a battery, comprising the steps of:

• providing a plurality of fiber anodes and a plurality of fiber cathodes;
• arranging the plurality of fiber anodes and fiber cathodes parallel to each other and in an bundled fashion within a flowable electrolyte;
• placing a compliant lateral casing laterally surrounding the fiber anodes, the fiber cathodes, and the electrolyte;
• and
• sealing a compliant end plate to each end of the lateral casing such that
• an end of each fiber anode extends out of a first end plate at a first end of the battery, and
• an end of each fiber cathode extends out of a second end plate at a second end of the battery.

A method for preparing a battery, comprising the steps of:

• drawing an anode fiber through a mass of negative battery paste so that battery paste adheres to the anode fiber, and curing the battery paste to form a fiber anode;
• drawing a cathode fiber through a mass of positive battery paste so that battery paste adheres to the cathode fiber, and curing the battery paste to form a fiber cathode;
• arranging the plurality of fiber anodes and fiber cathodes parallel to each other and in an alternating fashion;
• placing a compliant lateral casing around the sides of the fiber anodes, the fiber cathodes, and the electrolyte;
• placing a compliant end plate at each end of the lateral casing such that
• an end of each fiber anode extends out of a first end plate at a first end of the battery, and
• an end of each fiber cathode extends out of a second end plate at a second end of the battery;
• slicing off the fiber anode and cathode ends;
• and
• placing an electrically conductive material overlying the surfaces of the respective end plates.