Buckling resistant current collector

Patent metadata

Field	Value
Publication number	US-10854883-B2
Application number	US-201515518830-A
Country	US
Kind code	B2
Filing date	Oct 14, 2015
Priority date	Oct 16, 2014
Publication date	Dec 1, 2020
Grant date	Dec 1, 2020

Abstract

A wire mesh including a warp which includes a first nickel alloy wire having a first peak tensile strength; and a weft which includes a wire including nickel having a second peak tensile strength, wherein the first peak tensile strength is greater than or equal to the second peak tensile strength, is provided. A current collector and a zinc-air battery that includes the wire mesh are also provided.

First claim

What is claimed is:

1. A zinc-air battery comprising:
a zinc anode;
an air cathode comprising:
a wire mesh current collector comprising:
a warp comprising a first nickel alloy wire having a first peak tensile strength;
a weft comprising a wire comprising nickel and having a second peak tensile strength;

wherein:
the first peak tensile strength is greater than or equal to the second peak tensile strength; and
the first nickel alloy wire comprises 90 wt % to 99 wt % nickel and 1 wt % to 10 wt % aluminum.

2. The zinc battery of claim 1 , wherein the first nickel alloy wire has a resistivity of from about 2×10-7 Ωm to about 5×10-7 Ωm at 20° C.

3. The zinc battery of claim 1 , wherein the first nickel alloy wire has a peak tensile strength of greater than 140 ksi.

4. The zinc battery of claim 1 , wherein the wire comprising nickel has a peak tensile strength of greater than 60 ksi.

5. The zinc battery of claim 1 , wherein the mesh count of the wire mesh is from about 16×16 wires per inch to about 60×60 wires per inch.

6. The zinc battery of claim 1 , wherein the wire comprising nickel is a second nickel alloy wire.

7. The zinc battery of claim 6 , wherein the second nickel alloy wire comprises at least 90 wt % nickel and less than 10 wt % aluminum.

8. The zinc battery of claim 6 , wherein the second nickel alloy wire has a resistivity of from about 2×10-7 Ωm to about 5×10-7 Ωm at 20° C.

9. The zinc battery of claim 1 having a mesh density from about 0.1 to about 0.5.

10. The zinc battery of claim 1 , wherein the warp exhibits a microhardness from about 180 kgf/mm 2 to about 350 kgf/mm 2 , and the weft exhibits a microhardness from about 90 kgf/mm 2 to about 150 kgf/mm 2 .

11. The zinc battery of claim 1 , which is a woven mesh comprising a plain square weave, a twill square weave, plain Dutch weave, or a twill Dutch weave.

12. The zinc battery of claim 1 , wherein a wire of the warp exhibits a microhardness of about 160 kgf/mm 2 to about 350 kgf/mm 2 .

13. The zinc battery of claim 1 , wherein the first nickel alloy wire has a Young's Modulus of greater than 140 GPa.

14. A zinc-air battery comprising:
a zinc anode;
an air cathode;
a wire mesh current collector comprising:
a wire warp comprising a first nickel alloy, wherein the first nickel alloy wire comprises 90 wt % to 99 wt % nickel and 1 wt % to 10 wt % aluminum;
a wire weft comprising a second nickel alloy;

wherein:
the first and second nickel alloys are substantially insoluble in an aqueous caustic electrolyte;
the warp exhibits a microhardness from about 180 kgf/mm 2 to about 350 kgf/mm 2 , and the weft exhibits a microhardness from about 90 kgf/mm 2 to about 150 kgf/mm 2 ;
a wire of the warp prior to incorporation in the mesh exhibits a resistivity of from about 2×10 −7 Ωm to about 5×10 −7 Ωm at 20° C.;
a wire of the warp prior to incorporation in the mesh exhibits a peak tensile strength of greater than 140 ksi; and
a wire of the warp prior to incorporation in the mesh exhibits a Young's Modulus of from about 180 GPa to about 240 GPa.

15. A wire mesh comprising:
a warp comprising a first nickel alloy wire having a first peak tensile strength;
a weft comprising a wire comprising nickel and having a second peak tensile strength;
wherein:
the first peak tensile strength is greater than or equal to the second peak tensile strength; and
the first nickel alloy wire comprises 90 wt % to 99 wt % nickel and 1 wt % to 10 wt % aluminum.

16. The wire mesh of claim 15 , wherein the first nickel alloy wire has a peak tensile strength of from about 140 ksi to about 250 ksi.

17. The zinc battery of claim 1 , wherein first nickel alloy wire comprises from about 93 wt % to about 97 wt % nickel and from about 3 wt % to about 7 wt % aluminum.

18. The wire mesh of claim 15 , wherein first nickel alloy wire comprises from about 93 wt % to about 97 wt % nickel and from about 3 wt % to about 7 wt % aluminum.

19. The wire mesh of claim 15 , wherein wire comprising nickel has peak tensile strength of 80 ksi to 150 ksi.

Assignees

• Energizer Brands Llc

Inventors

• Mortensen Erik

Classifications

• H01M12/06

  with one metallic and one gaseous electrode · CPC title

• H01M4/75

  Wires, rods or strips · CPC title

• H01M4/747 Primary

  Woven material · CPC title

• H01M2300/0014

  Alkaline electrolytes · CPC title

• H01M4/745

  Expanded metal · CPC title