Electrical battery assembly and method of manufacture

An electrical storage battery made by the method of:

• providing a central support member;
• assembling a spiral sandwich member around the central support member, wherein the spiral sandwich member comprises:
• at least one positive electrode member;
• at least one negative electrode member;
• and
• a separator member physically separating the positive and negative electrode members from one another but allowing ionic contact between the positive and negative electrode members through an electrolyte;
• positioning the spiral sandwich member in a case;
• placing an electrolyte inside the case;
• electrically connecting one electrode member of the positive and negative electrode members to a first battery terminal through a flexible projecting member integral with the central support member, the flexible projecting member including a tab extending from an arm;
• and
• sealing the case.

A method for assembling an electrical storage battery, the method comprising:

• providing a central support member;
• assembling a spiral sandwich member comprising:
• at least one positive electrode member;
• at least one negative electrode member;
• and
• a separator member physically separating the positive and negative electrode members from one another but allowing ionic contact between the positive and negative electrode members through an electrolyte;
• enclosing the assembled spiral sandwich member in a case;
• placing an electrolyte inside the case;
• electrically connecting one electrode member of the positive and negative electrode members to a first battery terminal through a flexible projecting member on the central support member, the flexible projecting member including a tab extending from an arm;
• and
• sealing the case.

An electrical storage battery made by the method of:

• providing an electrode assembly including at least one positive electrode, at least one negative electrode, and at least one separator between the electrodes;
• installing the electrode assembly inside a case housing open at two ends;
• closing a first end of the case housing with a first cover, wherein an insulator isolates at least one of the electrodes from the first cover,
• electrically coupling one of the positive and negative electrodes with the case housing;
• electrically coupling the other of the positive and negative electrodes to a first battery terminal;
• electrically insulating the first battery terminal from the case housing;
• closing the second end of the case housing with a second cover having an electrolyte filling hole;
• placing an electrolyte inside the case tbrough the electrolyte filling hole;
• sealing the electrolyte filling hole with a plug member in electrical contact with the case housing, wherein the plug member includes a battery terminal pin, the plug member having a plug region configured to be positioned in the electrolyte filling hole, the plug member also having a pin region extending from a top of the plug region and having a narrower diameter than the top of the plug region, the pin region and plug region both being constructed of the same material as the cover.

A method for assembling an electrical storage battery, the method comprising:

• providing an electrode assembly including at least one positive electrode, at least one negative electrode, and at least one separator between the electrodes;
• installing the electrode assembly inside a case housing open at two ends;
• closing a first end of the case housing with a first cover, wherein an insulator isolates at least one of the electrodes from the first cover;
• electrically coupling one of the positive and negative electrodes to the case housing;
• electrically coupling the other of the positive and negative electrodes to a first battery terminal;
• electrically insulating the first battery terminal from the case housing;
• closing the second end of the ease housing with a second cover member having an electrolyte filling hole;
• placing an electrolyte inside the case through the electrolyte filling hole;
• sealing the electrolyte filling hole with a plug member in electrical contact with the case housing, wherein the plug member includes a battery terminal pin, the plug member having a plug region configured to be positioned in the electrolyte filling hole, the plug member also having a pin region extending from a top of the plug region and having a narrower diameter than the plug region, the pin region and plug region both being constructed of the same material as the cover.