Low cost electrical terminals manufactured from conductive loaded resin-based materials

Abstract

Electrical terminals are formed of a conductive loaded resin-based material. The conductive loaded resin-based material comprises micron conductive powder(s), conductive fiber(s), or a combination of conductive powder and conductive fibers in a base resin host. The percentage by weight of the conductive powder(s), conductive fiber(s), or a combination thereof is between about 20% and 50% of the weight of the conductive loaded resin-based material. The micron conductive powders are formed from non-metals, such as carbon, graphite, that may also be metallic plated, or the like, or from metals such as stainless steel, nickel, copper, silver, that may also be metallic plated, or the like, or from a combination of non-metal, plated, or in combination with, metal powders. The micron conductor fibers preferably are of nickel plated carbon fiber, stainless steel fiber, copper fiber, silver fiber, aluminum fiber, or the like.

What is claimed is: 
     
         1 . A battery device comprising:
 a battery storage cell having first and second internal electrodes;   a first external terminal connected to said first internal electrode; and   a second external terminal connected to said second internal electrode wherein at least one of said external terminals comprises a conductive loaded, resin-based material comprising conductive materials in a base resin host.   
     
     
         2 . The device according to  claim 1  wherein the percent by weight of said conductive materials is between about 20% and about 50% of the total weight of said conductive loaded resin-based material. 
     
     
         3 . The device according to  claim 1  wherein the percent by weight of said conductive materials is between about 20% and about 40% of the total weight of said conductive loaded resin-based material. 
     
     
         4 . The device according to  claim 1  wherein the percent by weight of said conductive materials is between about 25% and about 35% of the total weight of said conductive loaded resin-based material. 
     
     
         5 . The device according to  claim 1  wherein said conductive materials comprise metal powder. 
     
     
         6 . The device according to  claim 5  wherein said metal powder is nickel, copper, or silver. 
     
     
         7 . The device according to  claim 5  wherein said metal powder is a non-conductive material with a metal plating. 
     
     
         8 . The device according to  claim 7  wherein said metal plating is nickel, copper, silver, or alloys thereof. 
     
     
         9 . The device according to  claim 5  wherein said metal powder comprises a diameter of between about 3 μm and about 12 μm. 
     
     
         10 . The device according to  claim 1  wherein said conductive materials comprise non-metal powder. 
     
     
         11 . The device according to  claim 10  wherein said non-metal powder is carbon, graphite, or an amine-based material. 
     
     
         12 . The device according to  claim 1  wherein said conductive materials comprise a combination of metal powder and non-metal powder. 
     
     
         13 . The device according to  claim 1  wherein said conductive materials comprise micron conductive fiber. 
     
     
         14 . The device according to  claim 13  wherein said micron conductive fiber is nickel plated carbon fiber, or stainless steel fiber, or copper fiber, or silver fiber or combinations thereof. 
     
     
         15 . The device according to  claim 13  wherein said micron conductive fiber has a diameter of between about 3 μm and about 12 μm and a length of between about 2 mm and about 14 mm. 
     
     
         16 . The device according to  claim 13  wherein the percent by weight of said micron conductive fiber is between about 20% and about 40% of the total weight of said conductive loaded resin-based material. 
     
     
         17 . The device according to  claim 13  wherein said micron conductive fiber is stainless steel and wherein the percent by weight of said stainless steel fiber is between about 20% and about 40% of the total weight of said conductive loaded resin-based material. 
     
     
         18 . The device according to  claim 17  wherein said stainless steel fiber has a diameter of between about 3 μm and about 12 μm and a length of between about 2 mm and about 14 mm. 
     
     
         19 . The device according to  claim 1  wherein said conductive materials comprise a combination of conductive powder and conductive fiber. 
     
     
         20 . The device according to  claim 19  wherein said conductive fiber is stainless steel. 
     
     
         21 . The device according to  claim 1  wherein said base resin and said conductive materials comprise flame-retardant materials. 
     
     
         22 . The device according to  claim 1  further comprising a metal layer overlying said conductive loaded resin-based material. 
     
     
         23 . The device according to  claim 22  wherein said connection between said conductive loaded resin-based external terminal and said internal electrode is through said metal layer. 
     
     
         24 . The device according to  claim 1  further comprising a conductive paint layer overlying said conductive loaded resin-based material. 
     
     
         25 . The device according to  claim 24  wherein said connection between said conductive loaded resin-based external terminal and said internal electrode is through said conductive paint layer. 
     
     
         26 . The device according to  claim 1  wherein said battery storage cell is a wet cell. 
     
     
         27 . The device according to  claim 1  wherein said battery storage cell is a dry cell. 
     
     
         28 . The device according to  claim 1  wherein said battery is rechargeable. 
     
     
         29 . The device according to  claim 1  wherein said battery is a button type. 
     
     
         30 . The device according to  claim 1  further comprising a cable connected to one of said external terminals wherein said cable further comprises:
 a cable terminal; and 
 a cable core conductor. 
 
     
     
         31 . The device according to  claim 30  wherein said cable terminal comprises a conductive loaded, resin-based material comprising conductive materials in a base resin host. 
     
     
         32 . The device according to  claim 31  wherein said cable terminal further comprises a metal layer overlying said conductive loaded, resin-based material. 
     
     
         33 . The device according to  claim 30  wherein said cable core conductor comprises a conductive loaded, resin-based material comprising conductive materials in a base resin host. 
     
     
         34 . The device according to  claim 33  wherein said cable core conductor further comprises a metal layer overlying said conductive loaded, resin-based material. 
     
     
         35 . A battery device comprising:
 a battery storage cell having first and second internal electrodes;   a first external terminal connected to said first internal electrode; and   a second external terminal connected to said second internal electrode wherein at least one of said external terminals comprises a conductive loaded, resin-based material comprising conductive materials in a base resin host and wherein the percent by weight of said conductive materials is between about 20% and about 40% of the total weight of said conductive loaded resin-based material.   
     
     
         36 . The device according to  claim 35  wherein the percent by weight of said conductive materials is between about 25% and about 35% of the total weight of said conductive loaded resin-based material. 
     
     
         37 . The device according to  claim 35  wherein said conductive materials comprise metal powder. 
     
     
         38 . The device according to  claim 37  wherein said metal powder is a non-conductive material with a metal plating. 
     
     
         39 . The device according to  claim 37  wherein said metal powder comprises a diameter of between about 3 μm and about 12 μm. 
     
     
         40 . The device according to  claim 35  wherein said conductive materials comprise non-metal powder. 
     
     
         41 . The device according to  claim 35  wherein said conductive materials comprise a combination of metal powder and non-metal powder. 
     
     
         42 . The device according to  claim 35  wherein said conductive materials comprise micron conductive fiber. 
     
     
         43 . The device according to  claim 42  wherein said micron conductive fiber has a diameter of between about 3 μm and about 12 μm and a length of between about 2 mm and about 14 mm. 
     
     
         44 . The device according to  claim 42  wherein said micron conductive fiber is stainless steel. 
     
     
         45 . The device according to  claim 44  wherein said stainless steel fiber has a diameter of between about 3 μm and about 12 μm and a length of between about 2 mm and about 14 mm. 
     
     
         46 . The device according to  claim 35  wherein said conductive materials comprise a combination of conductive powder and conductive fiber. 
     
     
         47 . The device according to  claim 46  wherein said conductive fiber is stainless steel. 
     
     
         48 . The device according to  claim 35  further comprising a metal layer overlying said conductive loaded resin-based material. 
     
     
         49 . The device according to  claim 48  wherein said connection between said conductive loaded resin-based external terminal and said internal electrode is through said metal layer. 
     
     
         50 . The device according to  claim 35  further comprising a conductive paint layer overlying said conductive loaded resin-based material. 
     
     
         51 . The device according to  claim 50  wherein said connection between said conductive loaded resin-based external terminal and said internal electrode is through said conductive paint layer. 
     
     
         52 . The device according to  claim 35  wherein said battery storage cell is a wet cell. 
     
     
         53 . The device according to  claim 35  wherein said battery storage cell is a dry cell. 
     
     
         54 . The device according to  claim 35  wherein said battery is rechargeable. 
     
     
         55 . The device according to  claim 35  wherein said battery is a button type. 
     
     
         56 . The device according to  claim 35  further comprising a cable connected to one of said external terminals wherein said cable further comprises:
 a cable terminal; and 
 a cable core conductor. 
 
     
     
         57 . The device according to  claim 56  wherein said cable terminal comprises a conductive loaded, resin-based material comprising conductive materials in a base resin host. 
     
     
         58 . The device according to  claim 57  wherein said cable terminal further comprises a metal layer overlying said conductive loaded, resin-based material. 
     
     
         59 . The device according to  claim 56  wherein said cable core conductor comprises a conductive loaded, resin-based material comprising conductive materials in a base resin host. 
     
     
         60 . The device according to  claim 59  wherein said cable core conductor further comprises a metal layer overlying said conductive loaded, resin-based material. 
     
     
         61 . A method to form a battery device, said method comprising:
 providing a battery storage cell having first and second internal electrodes;   providing conductive loaded, resin-based material comprising conductive materials in a resin-based host;   molding said conductive loaded, resin-based material into an external terminal; and   connecting said external terminal to one of said internal electrodes.   
     
     
         62 . The method according to  claim 61  wherein the percent by weight of said conductive materials is between about 20% and about 40% of the total weight of said conductive loaded resin-based material. 
     
     
         63 . The method according to  claim 61  wherein said conductive materials comprise micron conductive fiber. 
     
     
         64 . The method according to  claim 63  wherein said micron conductive fiber is nickel plated carbon fiber, or stainless steel fiber, or copper fiber, or silver fiber or combinations thereof. 
     
     
         65 . The method according to  claim 63  wherein said micron conductive fiber has a diameter of between about 3 μm and about 12 μm and a length of between about 2 mm and about 14 mm. 
     
     
         66 . The method according to  claim 63  wherein the percent by weight of said micron conductive fiber is between about 20% and about 40% of the total weight of said conductive loaded resin-based material. 
     
     
         67 . The method according to  claim 63  wherein said micron conductive fiber is stainless steel and wherein the percent by weight of said stainless steel fiber is between about 20% and about 40% of the total weight of said conductive loaded resin-based material. 
     
     
         68 . The method according to  claim 67  wherein said stainless steel fiber has a diameter of between about 3 μm and about 12 μm and a length of between about 2 mm and about 14 mm. 
     
     
         69 . The method according to  claim 61  wherein said conductive materials comprise conductive powder. 
     
     
         70 . The method according to  claim 61  wherein said conductive materials comprise a combination of conductive powder and conductive fiber. 
     
     
         71 . The method according to  claim 61  wherein said molding comprises:
 injecting said conductive loaded, resin-based material into a mold; 
 curing said conductive loaded, resin-based material; and 
 removing said external terminal from said mold. 
 
     
     
         72 . The method according to  claim 61  wherein said molding comprises:
 loading said conductive loaded, resin-based material into a chamber; 
 extruding said conductive loaded, resin-based material out of said chamber through a shaping outlet; and 
 curing said conductive loaded, resin-based material to form said external terminal. 
 
     
     
         73 . The method according to  claim 61  further comprising subsequent mechanical processing of said molded conductive loaded, resin-based material. 
     
     
         74 . The method according to  claim 61  further comprising forming a metal overlying said molded conductive loaded, resin-based material. 
     
     
         75 . The method according to  claim 61  further comprising forming a conductive paint layer overlying said molded conductive loaded resin-based material. 
     
     
         76 . The method according to  claim 61  wherein said step of connecting said external terminal to one of said internal electrodes comprises press fitting said external terminal onto said internal electrode. 
     
     
         77 . The method according to  claim 61  wherein said step of connecting said external terminal to one of said internal electrodes occurs during said step of molding.