(19)
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`(12)
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`(cid:6)(cid:27)&(cid:11)(cid:11)(cid:12)(cid:19)(cid:19)(cid:17)(cid:14)(cid:17)(cid:15)(cid:24)(cid:12)(cid:6)
`EP 1 886 364 B1
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`(11)
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`EUROPEAN PATENT SPECIFICATION
`
`(45) Date of publication and mention
`of the grant of the patent:
`17.08.2011 Bulletin 2011/33
`
`(21) Application number: 06768597.4
`
`(22) Date of filing: 24.05.2006
`
`(51) Int Cl.:
`H01M2/10(2006.01)
`
`(86) International application number:
`PCT/KR2006/001946
`
`(87) International publication number:
`WO 2006/126831 (30.11.2006 Gazette 2006/48)
`
`(54) BATTERY AND METHOD FOR PRODUCING THE SAME
`
`BATTERIE UND VERFAHREN ZU IHRER HERSTELLUNG
`
`PILE ET PROCEDE DE FABRICATION CORRESPONDANT
`
`(84) Designated Contracting States:
`DE FI FR GB SE
`
`(30) Priority: 27.05.2005 KR 20050044929
`27.05.2005 KR 20050044930
`
`(43) Date of publication of application:
`13.02.2008 Bulletin 2008/07
`
`(73) Proprietor: E.M.W. Energy Co., Ltd.
`Geumcheon-gu, Seoul 153-803 (KR)
`
`(72) Inventors:
`• Ryou, Byung Hoon
`Raemian Bangbae Art Hill 109-1403
`Seoul 137-060 (KR)
`
`• Sung, Won Mo,
`1303-401 Daelim Apt.
`Gyeonggi-do 429-450 (KR)
`• MOON, Chang Soo,
`502, Sungdo Primevill
`Gyeonggi-do 422-090 (KR)
`
`(74) Representative: Rupprecht, Kay et al
`Meissner, Bolte & Partner GbR
`Widenmayerstraße 48
`80538 München (DE)
`
`(56) References cited:
`JP-A- 60 001 770
`JP-A- 2002 373 711
`US-A1- 2003 232 242
`
`JP-A- 2000 173 678
`JP-A- 2003 036 895
`
`
`Note: Within nine months of the publication of the mention of the grant of the European patent in the European Patent
`Bulletin, any person may give notice to the European Patent Office of opposition to that patent, in accordance with the
`Implementing Regulations. Notice of opposition shall not be deemed to have been filed until the opposition fee has been
`paid. (Art. 99(1) European Patent Convention).
`
`Printed by Jouve, 75001 PARIS (FR)
`
`EP1 886 364B1
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`EP 1 886 364 B1
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`Description
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`Technical Field
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`[0001] The present invention relates to a method of manufacturing a battery. More specifically, the invention relates
`to a method of manufacturing a standardized cylindrical zinc-air battery. Furthermore, the invention relates to a method
`of manufacturing a button cell battery having a variety of shapes in addition to the circular shape.
`
`Background Art
`
`[0002] Scaling down of electrical devices has long been attempted and thus many portable electronics have been
`developed. In recent years, however, as a new paradigm, called ubiquitous Internet, has been introduced, a small size
`and easy-carrying electronic devices have been being developed in a further extensive and intensive way. Most electronic
`devices such as MP3 players, digital cameras, mobile telephones, PDAs, laptop computers or the like are being developed
`into a compact and easily portable form. In addition to this miniaturization, an attempt has also been made to provide a
`variety of functions to a single device such as an MP3 phone, and a camera phone. While these attempts provide to
`users a freedom of movement and convenience of use, a stable supply of power should be associated therewith and
`currently draws attentions as a technical challenge to be solved.
`[0003] Conventionally, a battery has extensively been used as a power supplying means to electrical devices. Con-
`ventional batteries include a primary battery such as a manganese batter, an alkaline manganese battery and a zinc-
`air battery, and a secondary battery such as a Ni-Cd battery, a Ni-H battery, a lithium ion battery. Among them, the zinc-
`air battery has advantages of providing a relatively high voltage of 1.4V, and having a higher density of energy and a
`larger discharging capacity. Furthermore, since it exhibits a nearly constant discharging characteristic until being ex-
`hausted, the zinc-air battery is considered an alternative for the mercury battery, of which use is restricted because it
`contains heavy metals.
`[0004] The above zinc-air battery includes, in general, a cathode, an anode, a separator for isolating them, and an
`electrolyte. These elements are sealed by a cathode can and an anode can, both of which are made of a conductive
`material. The cathode can and anode can are contacted with the cathode and anode respectively to serves as a cathode
`terminal and an anode terminal respectively. In particular, in order to prevent leakage of the electrolyte from inside of a
`battery, the cathode can and anode can need to be sealed. Conventionally, a gasket is inserted between the cathode
`can and anode can, which are then crimped for hermetically sealing.
`[0005] These conventional button cell batteries are disclosed in U.S Patent No. 5,423,027, No. 5,486,431 issued to
`Tuttle, et al., Korean Patent No. 3060321, and the like. The conventional technology will be explained in detail, with
`reference to the accompanying drawings.
`[0006] FIG. 1 is a sectional view of the conventional button cell battery disclosed in the U.S. Patent No. 5,432,027.
`[0007] The button cell battery of FIG. 1 includes a cathode 14, an anode 12, a separator 16 interposed between them,
`and an electrolyte 18, which are sealed by a cathode can 20 and an anode can 22. In the seal 24, a gasket 26 is
`interposed between the cathode can 20 and the anode can 22 to seal them. The cathode can 20 is bent toward the
`anode can to cover the anode can 22, thereby performing a seal.
`[0008] FIG. 2 shows a method of manufacturing a button cell battery, which is disclosed in the Korean Patent No.
`3060321.
`[0009] As shown in FIG. 2(a), an anode 12 on an anode can 22, a separator 16, an electrolyte 18, a cathode 14 and
`a gasket 26 are disposed in sequence, which are covered by a cathode can 20. Then, as shown in FIG. 2(b), the outer
`peripheral region of the cathode can 20 is crimped towards the anode can 22 to seal the inside of the battery.
`[0010] As described above, in the conventional battery manufacturing process, a can is crimped to seal the battery,
`so that the process can be simplified. When the cathode can 20 is crimped, however, a pressure is exerted on the central
`portion of the cathode can 20, which is to be contacted with the cathode 14, thereby causing a deformation. In the case
`where the crimping pressure is increased in order to improve the precision of sealing, the above problem becomes
`worse. In addition, the gasket 26 interposed between the cathode can 20 and the anode can 22 leads to a further
`complicated manufacturing process.
`[0011]
`In addition, in case of manufacturing a circular button cell battery, the conventional crimping method is suitable,
`while in case where a polygonal-shaped battery such as a rectangular or pentagonal one is preferred, the crimping is
`overlapped at the corners of a polygon and thus the crimping method is not applicable to the manufacturing of polygonal
`batteries.
`[0012] FIG. 3 is a sectional view of a conventional button type zinc-air battery.
`[0013] Referring to FIG. 3, the conventional button type zinc-air battery includes a membrane as a cathode 14 and a
`zinc gel as an anode 12, and a separator 15 interposed between the membrane and the zinc gel. In addition, the
`membrane and the zinc gel are accommodated inside the cathode can 20 and the anode can 22 respectively to resultantly
`
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`EP 1 886 364 B1
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`form a battery.
`[0014] The membrane is a permeable membrane containing water molecules and generates hydroxyl ions (OH-) by
`contacting oxygen in air. This reaction may be expressed by the following chemical equation.
`[0015]
`
`O2 + 2H2O + 4e- ↔ 4OH-
`
`ChemistryFigure 1
`
`[0016]
`In the above reaction, electrons are supplied through the cathode can 20. The membrane is commonly made
`of carbon, but may be formed of other suitable materials, depending on the required voltage or its applications.
`[0017]
`In this way, since the cathode reaction needs oxygen, the cathode must be provided with a path capable of
`contacting air. Thus, the cathode can 20 is provided with an air hole 21 formed at its bottom. When a batter is not used,
`the air hole 21 is sealed to suppress the cathode reaction.
`[0018] The hydroxyl ions generated through the above chemical reaction are transferred to the zinc gel, which is an
`anode, through the separator 16. The separator 16 is permeable for hydroxyl ions, and on the other hand functions to
`prevent leakage of the zinc gel and to provide insulation between the zinc gel and the membrane.
`[0019] The zinc gel contains mainly zinc powder and is mixed with additives and an electrolyte. Commonly, the
`electrolyte employs an aqueous solution of potassium hydroxide (KOH). If hydroxyl ions are transferred inside of the
`zinc gel, the zinc powder reacts with the hydroxyl ions to be oxidized. This reaction can be expressed by the following
`chemical equation.
`[0020]
`
`Zn + 2OH- ↔ Zn(OH)2 + 2e-Zn + 2OH- ↔ ZnO + H2O + 2e-
`
`ChemistryFigure 2
`
`[0021] Due to this reaction, electrons are generated from the anode and the electrons are transferred through the
`anode can 22. Through this chemical reaction, theoretically a voltage of 1.65V can be derived at maximum.
`[0022] The conventional zinc-air batteries are mostly implemented as a button cell type. In the button cell type zinc-
`air battery, similarly, hermetical sealing of the battery is performed through crimping of can. A conventional method of
`manufacturing a zinc-air battery is disclosed in Japanese Patent Laid-open Publication No. 2002-373711.
`[0023] Referring to FIG. 4, the conventional manufacturing method of a zinc-air battery will be explained. The zinc-air
`battery includes a zinc gel 12 as an anode, a cathode membrane 14 as a cathode, and a separator 16 for insulating
`them. The zinc gel 12 and the cathode membrane 14 are surrounded and held by an anode can 22 and a cathode can
`20 connected thereto. On the other hand, formed in the cathode can 20 is a through-hole 28 for contacting the cathode
`membrane 14 with air.
`[0024] At the can distal area, a gasket 26 is interposed between the anode can 22 and the cathode can 20, and the
`cathode can 20 and the gasket 26 are crimped towards the anode can 22 to thereby seal the battery.
`[0025] Such zinc-air batteries have favorable properties in terms of energy density, and discharging capacity and
`characteristic. But use of the conventional zinc-air battery has been limited to special areas such as hearing aids, cameras
`or the like. In particular, such zinc-air batteries have been commercialized as a button type battery only, but have not
`been manufactured in cylindrical standard types such as AAA, AA and the like. In order to commercialize a cylindrical
`zinc-air battery, they must be manufactured so as to generate a voltage and current suitable to the applications of the
`cylindrical batteries. Also, a manufacturing process must be developed so as to allow the zinc-air batteries to be made
`in a cylindrical form.
`[0026] Referring to FIG. 5, problems in manufacturing conventional cylindrical zinc-air battery will be explained as
`follows.
`[0027] FIG. 5 is a sectional view of an imaginary cylindrical zinc-air battery. In FIG. 5, identical elements to FIG. 3 are
`denoted by same reference numerals. Since a zinc-air battery contains a zinc gel as an anode, leakage of the zinc-gel
`must be avoided. In the conventional button type battery shown in FIG. 3, disposed underneath the zinc gel are a cathode
`membrane 14 and a separator 16 to prevent the zinc-gel from being leaked, thus leading to an easy fabrication. Since
`as shown in FIG. 5, however, a cylindrical battery is configured such that a separator 16 and a cathode membrane 14
`capture the zinc gel, in order to form a cylindrical form, the cathode membrane 14 and the separator 16 need to have
`bonding areas 30 and 32, thus causing difficulties in blocking leakage of the zinc gel.
`[0028] Therefore, in order to fabricate a cylindrical zinc-air battery, there needs to provide a method of bonding the
`separator 12 and the cathode membrane 14 while preventing the zinc gel from being leaked.
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`Disclosure of Invention
`
`Technical Problem
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`[0029] Accordingly, the present invention has been made in order to solve the above problems, and it is an object of
`the invention to provide a method of manufacturing a button cell battery, in which a separate gasket is not necessitated
`to be interposed between an anode can and a cathode can and deformation of cans by crimping can be avoided.
`[0030] Another object of the invention is to provide a method of manufacturing a button cell battery, which is applicable
`to a polygonal button cell battery in addition to a circular button cell battery.
`[0031] A further object of the invention is to provide a method of manufacturing a zinc-air battery, which can be applied
`to a polygonal button cell battery while preventing deformation of a can.
`[0032] A further object of the invention is to provide a cylindrical zinc-air battery and a method of manufacturing the
`same, in which leakage of zinc-gel is blocked.
`
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`Technical Solution
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`[0033]
`In order to accomplish the above objects of the invention, according to one aspect of the invention, there is
`provided a battery comprising: an anode; a cathode; an anode can disposed to enable electrons to transfer against the
`anode; a cathode can disposed to enable electrons to transfer against the cathode; and a body forming a battery body,
`wherein one end of the body is fusion-bonded with an end portion of the anode can and the other end of the body is
`fusion-bonded to an end portion of the cathode can, thereby hermetically sealing the battery.
`[0034] According to another aspect of the invention, there is provided a zinc-air battery comprising: a cathode mem-
`brane serving as a cathode; a zinc gel serving as an anode; a cathode can disposed to enable electrons to transfer
`against the cathode membrane; an anode can disposed to enable electrons to transfer against the zinc gel; and a body
`forming a battery body, wherein one end of the body is fusion-bonded with an end portion of the anode can and the
`other end of the body is fusion-bonded to an end portion of the cathode can, thereby hermetically sealing the battery.
`[0035] According to a further aspect of the invention, there is provided a zinc-air battery including a zinc gel serving
`as an anode and a cathode membrane serving as a cathode and capturing the zinc gel, wherein both end portions of
`the cathode membrane face each other with a gap in-between, and the gap is filled with a resin.
`[0036] According to another aspect of the invention, there is provided a zinc-air battery including a zinc gel serving
`as an anode and a cathode membrane serving as a cathode and capturing the zinc gel, wherein both end portions of
`the cathode membrane are overlapped and fusion-bonded.
`[0037] According to another aspect of the invention, there is provided a cylindrical zinc-air battery comprising: a zinc
`gel serving as an anode; a cathode membrane serving as a cathode and capturing and hermetically sealing the zinc gel
`in a cylindrical form; a housing capturing the cathode membrane in a cylindrical form and having an opening formed
`therein for allowing air to pass through; and an insulator interposed between the cathode membrane and the housing
`and having an opening formed therein for allowing air to pass through.
`[0038] According to another aspect of the invention, there is provided a method of manufacturing a battery, the battery
`including a first electrode, a second electrode, a first can disposed so as to allow electrons to transfer against the first
`electrode, a second can disposed so as to allow electrons to transfer against the second electrode, and a body constituting
`the battery body, the method comprising: a first fusion-bonding step in which an end portion of the first can is fusion-
`bonded with one end of the body; and a second fusion-bonding step in which an end portion of the second can is fusion-
`bonded with the other end of the body.
`[0039] According to another aspect of the invention, there is provided a method of manufacturing a zinc-air battery,
`the zinc-air battery including a cathode membrane serving as a cathode, a zinc gel serving as an anode, a cathode can
`disposed so as to allow electrons to transfer against the cathode membrane, an anode can disposed so as to allow
`electrons to transfer against the zinc gel, and a body constituting the battery body, the method comprising: a first fusion-
`bonding step in which an end portion of the anode can is fusion-bonded with one end of the body; and a second fusion-
`bonding step in which an end portion of the cathode can is fusion-bonded with the other end of the body.
`[0040] According to another aspect of the invention, there is provided a method of manufacturing a zinc-air battery,
`the zinc-air battery including a zinc gel serving as an anode and a cathode membrane serving as a cathode and capturing
`the zinc gel, the method comprising the steps of: disposing the cathode membrane such that both end portions thereof
`face each other with a gap in-between; and filling the gap with a resin and fusion-bonding the both end portions with the
`resin.
`[0041] According to another aspect of the invention, there is provided a method of manufacturing a zinc-air battery,
`the zinc-air battery including a zinc gel serving as an anode, and a cathode membrane serving as a cathode and capturing
`the zinc gel, the method comprising the steps of: disposing the cathode membrane such that both end portions thereof
`are overlapped; and fusion-bonding the overlapped both end portions of the cathode membrane to each other.
`
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`EP 1 886 364 B1
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`[0042] According to another aspect of the invention, there is provided a method of manufacturing a cylindrical zinc-
`air battery, the zinc-air battery including a zinc gel serving as an anode and a cathode membrane serving as a cathode,
`the method comprising the steps of: hermetically sealing the cathode membrane in a cylindrical form; filling the zinc gel
`inside of the cathode membrane; inserting the filled cathode membrane into a cylindrical insulator; and forming a housing
`coating the insulator.
`
`Advantageous Effects
`
`[0043] According to the invention, deformation of a can caused by can-crimping is prevented to improved reliability of
`contact between the can and an electrode (or MEA) and battery performance.
`[0044]
`In addition, a cathode can and an anode can are not overlapped, thereby eliminating necessity of a separate
`gasket and thus simplifying the manufacturing process thereof.
`[0045] Furthermore, the hermetical sealing of battery does not require can-crimping, thus enabling to fabricate various
`shapes of battery having a polygonal transversal cross-section, as well as a circular cross-section.
`[0046]
`In particular, where the invention is applied to a zinc-air battery, the shape of the zinc-air battery can be
`diversified, departing from the conventional circular button cell type, thus broadening the application range of a zinc-air
`battery.
`[0047]
`In addition, according to the invention, leakage of zinc gel can be prevented in a cylindrical zinc-air battery.
`[0048] Furthermore, according to the invention, a cylindrical zinc-air battery not causing leakage of zinc gel can be
`fabricated, so that the zinc-air battery can be standardized to the universal AAA to A types.
`
`Brief Description of the Drawings
`
`[0049] Further objects and advantages of the invention can be more fully understood from the following detailed
`description taken in conjunction with the accompanying drawings in which:
`[0050] FIG. 1 is a sectional view of a conventional button cell battery;
`[0051] FIG. 2 shows a conventional method of manufacturing a button cell battery;
`[0052] FIG. 3 is a sectional view of a conventional button-type zinc-air battery;
`[0053] FIG. 4 is a sectional view of a conventional button cell zinc-air battery;
`[0054] FIG. 5 is a sectional view of an imaginary cylindrical zinc-air battery
`[0055] FIG. 6 is a sectional view of a button-cell battery according to an embodiment of the invention;
`[0056] FIG. 7 is an enlarged view of a fusion-bonded region of the can and the body in the battery of FIG. 6;
`[0057] FIG. 8 is a flow chart illustrating a method of manufacturing a button cell battery according to an embodiment
`of the invention;
`[0058] FIGS. 9 to 11 are flow charts showing a method of fusion-bonding the can and the body in FIG. 11;
`[0059] FIG. 12 is a flow chart showing a method of manufacturing a button cell battery according to another embodiment
`of the invention;
`[0060] FIG. 13 is a flow chart showing a method of manufacturing a button cell zinc-air battery according to another
`embodiment of the invention;
`[0061] FIG. 14 is a flow chart showing a method of manufacturing a button cell zinc-air battery according to another
`embodiment of the invention;
`[0062] FIG. 15 illustrates a transversal cross-section of a cylindrical zinc-air battery according to another embodiment
`of the invention;
`[0063] FIGS. 16 and 17 illustrate a method of manufacturing a cylindrical zinc-air battery according to another em-
`bodiment of the invention;
`[0064] FIG. 18 illustrates a transversal cross-section of a cylindrical zinc-air battery according to another embodiment
`of the invention; and
`[0065] FIG. 19 illustrates a method of manufacturing a cylindrical zinc-air battery according to another embodiment
`of the invention.
`
`Best Mode for Carrying Out the Invention
`
`[0066] Hereinafter, the preferred embodiments of the present invention will be described in detail with reference to
`the accompanying drawings.
`[0067] FIG. 6 is a sectional view of a button cell battery according to an embodiment of the invention.
`[0068] The button cell battery of this embodiment includes a first can 52 and a second can 54 having a U-shape cross-
`section, and a body 56. Inserted inside of these are a first electrode 42 and a second electrode 44, a separator 46 for
`insulating them, and an electrolyte 48.
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`[0069] The first and second electrodes 42 and 44 are accommodated inside of the U-shape cans 52 and 54. The end
`portion 60 of the cans 52 and 54 is protruded higher than the electrodes 42 and 44. The first and second cans 52 and
`54 are made of a conductive material and may be fabricated through a pressing process. The first electrode 42 is
`contacted with the first can 52 for electrons to be able to transfer and thus the first can 52 serves as an external terminal
`of the first electrode 42. Similarly, the second can 54 contacts the second electrode 44 to serve as an external terminal
`of the second electrode 44.
`[0070] The separator 46 is made of a porous material to prevent the first and second electrodes 42 and 44 from being
`directly contacted with each other and at the same time allows electrons to be transferred through the electrolyte 48.
`[0071]
`In this embodiment, hermetical sealing of the battery may be carried out by fusion-bonding of the cans 52 and
`54 and the body 56. The body 56 is made of an insulation resin and insulates the first and second cans 52 and 54 from
`each other and also is fused at the end portion 60 of the cans 52 and 54 to seal the inside of the battery. The fusion-
`bonding of the body 56 and the cans 52 and 54 may be performed using ultrasonic, pressing, heating or the like, which
`will be hereafter described.
`[0072] On the other hand, the shape of the end portion 60 of the cans 52 and 54 may be changed in order to improve
`reliability of the fusion-bonding.
`[0073] FIG. 7 is an enlarged view of the fusion-bonded region of the first can and the body.
`[0074] As illustrated in FIG. 7(a), a through-hole 62a may be formed at the end portion of the can 52, which is fusion-
`bonded with the body 56. In this case, the melted body 56 fills the inside of the through-hole 62a. Thus, after curing of
`the body 56, reliability of the bonding of the can 52 and the body 56 can be improved. In addition, as shown in FIGS. 7
`(b) and 7(c) respectively, a protrusion or a depression may be formed at the end portion of the can 52, thereby improving
`reliability for the bonding of the can 52 with the body 56.
`[0075] Hereafter, referring to FIGS. 6 and 8, a manufacturing method of a button cell battery according to an embodiment
`of the invention will be explained. The method of this embodiment starts from step 100. At the step 100, a first electrode
`42 is disposed on a first can 52 and a second electrode 44 is disposed on a second can 54 to thereby form an assembly
`of can and electrode. The electrodes 42 and 44 are accommodated inside of the cans 52 and 54 such that the end
`portion 60 of the cans 52 and 54 can be protruded.
`[0076] Then, at step 110, the second can 54 is fusion-bonded to one end of the body 56. Referring to FIGS. 9 to 11,
`a method of fusion-bonding the second can 54 with the body 56 will be explained in details.
`[0077] As illustrated in FIG. 9, the fusion-bonding of the second can 54 and the body 56 may be performed after the
`body 56 is first melted. Specifically, first, one end of the body 56 is melted (step 110a), and then the second can 54 is
`disposed at one end of the body 56 (step 110b). Although the body 56 generally is melted by heating, pressurization or
`ultrasonic radiation can be used. The melting method may be selected depending on the body 56 material.
`[0078] Thereafter, the second can 54 is pressurized and the end portion of the can is inserted into the inside of the
`body 56 (step 110c). The body 56 is cooled and cured to fusion-bond the second can 54 and the body 56 (step 110d).
`[0079] On the other hand, first, the second can 54 may be disposed at one end of the body 56, which is then heat-
`melted such that the end portion of the can 54 can be inserted into the body 56 by the weight of the can 54 and fusion-
`bonded thereto.
`[0080] Alternatively, as shown in FIG. 10, the second can 54 is heated to carry out a fusion-bonding. In this case, the
`second can 54 is heated to a desired temperature (step 110e). Then, the second can 54 is disposed at one end of the
`body 56 and the end portion of the second can 54 is pressure-inserted inside of the body 56 (step 110f). At this step,
`the end portion of the can 54 melts the body 56 and simultaneously is inserted into inside of the body 56. Finally, the
`body 56 is cooled and cured to complete the fusion-bonding (step 110g). The heating temperature of the can 54 may
`be determined according to the melting temperature of the body 56, the inserting pressure, or the like.
`[0081] As shown in FIG. 11, the fusion-bonding of the second can 54 and the body 56 may be performed through an
`in-mold forming process. Specifically, the second can 54 is inserted into a metallic mold (step 110h). An injection-molding
`space of the body 56 shape is formed in the metallic mold. Then, at step 110i, a resin is injected and the body 56 is
`injection-molded, thereby forming a fusion-bonded assembly of the body 56 and the second can 54.
`[0082] Referring to FIG. 8 again, at step 120, a separator 46 is disposed at a space formed by the fusion-bonding of
`the body 56 and the second can 54 and an electrolyte 48 is filled. Finally, the first can 52 combined with the first electrode
`42 is fusion-bonded to the other end of the body 56 to complete hermetical sealing of the battery (step 130). Fusion-
`bonding of the first can 52 and the body 56 may be carried out in the same way as in the second can 54 and the body
`56, which is described above, in conjunction with FIGS. 9 to 11.
`[0083] As described above, in this embodiment, without crimping the cans 52 and 54, they are fusion-bonded with the
`body 56 to seal the battery, thereby enabling to prevent deformation of a can, which occurs at the central portion of the
`cans 52 and 54 when they are bent or crimped. Therefore, reliability of contact between the can 52, 54 and the electrode
`42, 44 can be improved and the battery performance can be enhanced.
`[0084]
`In addition, as long as the cans 52 and 54 have a U-shaped cross-section, they may be manufactured in the
`form of a polygon as well as a circular. Thus, the present invention can be applied to manufacturing of polygonal button
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`EP 1 886 364 B1
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`cell batteries and thus applications of the battery can be extended into a variety of fields.
`[0085]
`In the above embodiments, the second can 54 is fusion-bonded before the first can 52, but the first can 52 may
`be first fusion-bonded or the first and second cans 52 and 54 may be simultaneously fusion-bonded.
`[0086] Referring to FIG. 12, specifically, a method of manufacturing a button cell battery according to another embod-
`iment of the invention will be explained. In this embodiment, in the same way as in FIG. 8, it starts with formation of an
`assembly of a can and electrode (Step 200). Then, a second can 54 is disposed at one end of the body 56 (step 210),
`and a separator 46 and an electrolyte 48 are inserted inside of the space formed by the body 56 and the second can
`54 (step 220). Thereafter, at step 230, a first can is disposed at the other end of the body 56.
`[0087] Finally, at step 240, both ends of the body 56 are melted and, after the end portions of the cans 52 and 54 are
`inserted into the inside of the body 56, the body 56 is cooled and cured to fusion-bond the body 56 with the cans 52 and
`54. The fusion-bonding at the step 240 may be performed in various ways, which are previously described in conjunction
`with FIGS. 9 to 11.
`[0088]
`In this embodiment, two cans are fusion-bonded at the same time. Thus, the manufacturing process can be
`simplified to thereby improve the efficiency of battery production.
`[0089] The present invention may be applied to the manufacturing of a zinc-air battery.
`[0090] FIG. 13 is a sectional view illustrating a button cell zinc-air battery according to another embodiment of the
`invention.
`[0091] The zinc-air batter of this embodiment includes a cathode can 72 and an anode can 74 having U-shaped cross-
`sections, and a body 56. The cathode can 72 accommodates a membrane electrode assembly (MEA) 65, which is
`contacted with the cathode can 72. In addition, the inside of the battery is filled with a zinc gel 66 serving as an anode.
`The cathode can 72 and the anode can 74 are formed of a conductive material and can serve as a cathodic external
`terminal and an anodic external terminal respectively. On the other hand, the cathode can 72 is formed with a through-
`hole 68 such that the MEA 65 can be contacted with air.
`[0092]
`In the zinc-air battery of this embodiment, the cathode can 72 and the anode can 74 are fusion-bonded to the
`body 56 to thereby seal the battery. The fusion-bonding of the body 56 with the cathode can 72 and the anode can 74
`is carried out in the same way as in the previous embodiments of FIGS. 6 and 7 and thus details thereon will not be
`repeated here.
`[0093] Hereafter, a manufacturing method of a button cell zinc-air battery according to yet another embodiment of the
`invention will be explained, referring to FIGS. 13 and 14.
`[0094] According to this embodiment, at step 300, an anode can 74 is fusion-bonded to one end of the body 56. The
`fusion-bonding of the anode can 74 and the body 56 may be carried out in various ways, which are previously explained
`in conjunction with FIG. 7.
`[0095] Thereafter, a zinc gel 66 is filled in the internal space formed by the assembly of the anode can 74 and the
`body 56 (step 310). The fusion-bonding of the body 56 and the anode can 74 seals the fusion area of them, thereby
`preventing leakage of the zinc gel 66.
`[0096] At step 320, a cathode can 72 is fusion-bonded to the other end of the body 56. The cathode can 72 is pre-
`assembled with an MEA 65, or an anode membrane and a separator, and the end portion 60 of the cathode can 72 is
`protruded higher than the MEA 65. In this step, the end portion 60 of the protruded cathode can 72 is fusion-bonded to
`the other end of the body 56. The fusion-bonding of the cathode can 72 and the body 56 may be performed in various
`ways, which are previously explained in conjunction with FIGS. 9 to 11. In this way, the fusion-bonding of the cathode
`can 72 and the body 56 completes hermetical sealing of the battery.
`[0097]
`In this embodiment, the anode can 74 and