Abstract: An electrochemical cell is provided with an enhanced pressure relief vent formed in a closed end of the cell container that allows for effective venting of gas from the closed end of the container. The cell includes a container having a first end, a second end, a side wall extending between the first and second ends, and an end wall extending across the first end. The cell has a positive electrode, a negative electrode, and an aqueous alkaline electrolyte, all disposed in the container. The cell further includes a pressure relief vent mechanism having a reduced thickness groove formed in the end wall of the container. A cover is welded to the closed end wall of the container over the pressure relief vent mechanism and is welded via at least three welds, wherein two adjacent welds are angularly separated by more than 120°.

Abstract: A battery package comprising a backing having a first area and a second area. The package also includes a first compartment extending from the first area of the backing, a second compartment extending from the second area of the backing, and batteries in the first compartment and the second compartment. The backing has a first position wherein the first compartment and the second compartment are closed and the batteries therein cannot be removed from the first compartment and the second compartment, with the first compartment closing the second compartment and the second compartment closing the first compartment. The backing has a second position wherein the first compartment and the second compartment are open and the batteries therein can be removed.

Abstract: An alkaline electrochemical cell containing a neat multiphase thermoplastic polymer separator is disclosed. The microstructure and composition of the polymer are selected to provide a film that can physically endure the rigors of a cell assembly process and also provide adequate ionic conductivity to support a high rate discharge. In one embodiment, the ionic conductivity of the separator is improved upon contact with the cell's alkaline electrolyte. Processes that can be used to manufacture a cell of this invention are also described.

Abstract: An air depolarized battery with an improved sealing member for sealing the air inlet port(s) of the battery before use is disclosed. The sealing member has areas of relatively high and low permeability, with an area of low permeability over at least a portion of an air inlet port. The sealing member may comprise a plurality of layers, where the area of highest permeability includes a portion of the lowest permeability layer that has a higher permeability than a surrounding portion thereof. The rate of flow of air through the low permeability area and into the battery can be easily modified to maintain a desired battery open circuit voltage during battery storage to allow activation of the battery within a short time after removal of the sealing member, while minimizing losses in discharge capacity before use.

Abstract: A cylindrical alkaline electrochemical cell is disclosed that includes a gel free anode. The anode includes a free flowing zinc powder with a preassembly tap density between 1.6 g/cc and 2.9 g/cc. In one embodiment, zinc powder with the desired tap density may be obtained by mixing zinc agglomerates with zinc flakes.

Abstract: An electrochemical battery cell in accordance with the invention has a high electrode interfacial surface area to improve high rate discharge capacity, and the shapes of the electrodes facilitate the manufacture of cells of high quality and reliability at high speeds suitable for large scale production. The interfacial surfaces of the solid body electrodes have radially extending lobes that increase the interfacial surface area. The lobes do not have sharp corners, and the concave areas formed between the lobes are wide open, to facilitate assembly of the separator and insertion of the other electrode into the concave areas without leaving voids between the separator and either electrode.

Abstract: An electrochemical cell with a vent assembly that reliably prevents resealing of a vented seal member is provided. The vent assembly seals the end of a container that includes a first electrode, a second electrode, a separator located between the first and second electrodes and an electrolyte in contact with the electrodes and separator. The seal member includes a diaphragm with a hinge along one edge and a vent along another edge. The hinge and vent are located so that, relative to the longitudinal axis of the vent assembly, the hinge is closer to the vent than to the cell's terminal cover.

Abstract: An active manganese dioxide electrode material that exhibits improved electrochemical performances compared with conventional manganese dioxide materials includes at least one dopant. The doped manganese dioxide electrode materials may be produced by a wet chemical method (CMD) or may be prepared electrolytically (EMD) using a solution containing manganese sulfate, sulfuric acid, and a dopant, wherein the dopant is present in an amount of at least about 25 ppm.

Abstract: An electrochemical battery cell with CuxO, where x is from 0.9 to 1.3, as a positive electrode active material. The specific surface area of the CuxO is from 1.0 to 4.0 m2/gram, preferably from 1.0 to 2.9 m2/g to provide an increase in the high voltage discharge capacity of the CuxO.

Abstract: A battery dispenser and a refill for a battery dispenser are provided. In one embodiment the battery dispenser includes a disk that supports a plurality of batteries, a cover that has an opening, a grip ring that rotates the disk to align the batteries with the opening of the cover, and a push element capable of advancing batteries from inside the cover to a landing external to the cover. The disk rotates relative to the grip ring between a load position and a dispensing position, and the disk is removable from the grip ring when the disk is in the load position.

Abstract: An electrochemical battery cell with an oxygen reduction electrode and having improved electrolyte leakage resistance. The cell includes a component, disposed between the oxygen reduction electrode and an air inlet in the cell housing, through or around which air can pass. Upon contact with electrolyte, the component is transformed to form an electrolyte seal.

Abstract: Processes for making rigid, binder free agglomerates of powdered metal are disclosed. The agglomerates have a low tap density. Articles that contain binder free agglomerates made from electrochemically active powder are also disclosed.

Abstract: Various embodiments of a metal-air cell having a tab system that covers an air entry port of the metal-air cell are provided. In one representative embodiment the tab system includes polymer layer and an adhesive layer between the metal-air cell and the polymer layer. The tab system has a loss stiffness of less than 55,000 N/m at 20° C. to 25° C.

Abstract: A fluid regulating microvalve assembly for use to control fluid flow to a fluid consuming electrode, such as an oxygen reduction electrode, in an electrochemical cell. The microvalve assembly includes a stationary valve body having an aperture and a microactuator movable from a first position where the microvalve body aperture is closed to fluid flow to at least a second position where fluid is able to pass through the microvalve body aperture. The fluid regulating microvalve assembly can utilize cell potential or a separate source to open and close the microvalve. The fluid regulating microvalve assembly can be located outside the cell housing or inside the cell housing, for example between one or more fluid inlet apertures and the fluid consuming electrode. The invention includes a method of making a multilayer microvalve assembly, particularly one for use in a fluid depolarized battery, using a printing process to deposit at least one of the layers.

Abstract: An electrochemical cell with a blended zinc powder is disclosed. The blended zinc powder includes selected portions of a first zinc powder and a second zinc powder. In a preferred embodiment, the first and second powders are divided into groups based on ranges in their particle size distribution. Particle characteristics such as roughness and elongation are used to selected groups of both powders that are combined to produce the blended zinc powder. The blended zinc powders enable battery manufacturers to maximize the cell's run time while minimizing the cost of the zinc.

Abstract: An alkaline battery cell with improved high rate and high power discharge capacity is provided, without sacrificing capacity at low rate and low power, by adding at least a second anode or cathode, reducing the effective maximum electrode thicknesses, and increasing the active material density in one or more electrodes.

Abstract: An alkaline battery cell with increased discharge capacity is provided. Both the internal volume and the electrode interfacial surface area are increased, without unnecessarily increasing the overall cell volume, by increasing the height but not the diameter of the electrodes, thereby avoiding an unnecessary increase in the total cell volume.