Abstract: A process for making a catalytic electrode, a process for making an electrochemical cell with a catalytic electrode, and an electrochemical cell made according to the process. The catalytic electrode has an active layer comprising a catalytic material, an electrically conductive material and a binder, and a gas diffusion layer including a material that is permeable to gas entering or escaping from the cell but essentially impermeable to electrolyte. The gas diffusion layer is adhered to the active layer by a patterned pressure bonding process to provide the catalytic electrode in which the entire gas diffusion area is adhered to the active layer, with areas of relatively high and relatively low adhesion. The electrode has a high overall bond strength, and the permeability of the gas diffusion layer remains high it has been adhered to the active layer to provide excellent high power capability.

Abstract: A process for making a catalytic electrode, a process for making an electrochemical cell with a catalytic electrode, and an electrochemical cell made according to the process. The catalytic electrode has an active layer comprising a catalytic material, an electrically conductive material and a binder, and a gas diffusion layer including a material that is permeable to gas entering or escaping from the cell but essentially impermeable to electrolyte. The gas diffusion layer is adhered to the active layer by a patterned pressure bonding process to provide the catalytic electrode in which the entire gas diffusion area is adhered to the active layer, with areas of relatively high and relatively low adhesion. The electrode has a high overall bond strength, and the permeability of the gas diffusion layer remains high it has been adhered to the active layer to provide excellent high power capability.

Abstract: A process for making a catalytic electrode, a process for making an electrochemical cell with a catalytic electrode, and an electrochemical cell made according to the process. The catalytic electrode has an active layer comprising a catalytic material, an electrically conductive material and a binder, and a gas diffusion layer including a material that is permeable to gas entering or escaping from the cell but essentially impermeable to electrolyte. The gas diffusion layer is adhered to the active layer by a patterned pressure bonding process to provide the catalytic electrode in which the entire gas diffusion area is adhered to the active layer, with areas of relatively high and relatively low adhesion. The electrode has a high overall bond strength, and the permeability of the gas diffusion layer remains high it has been adhered to the active layer to provide excellent high power capability.

Abstract: An electrochemical cell constructed in accordance with the present invention includes a can for containing electrochemical materials including positive and negative electrodes and an electrolyte, the can having an open end and a closed end; a pressure relief mechanism formed in the closed end of the can for releasing internal pressure from within the can when the internal pressure becomes excessive; a first outer cover positioned on the closed end of the can to be in electrical contact therewith and to extend over the pressure relief mechanism; a second outer cover positioned across the open end of the can; and an insulator disposed between the can and the second outer cover for electrically insulating the can from the second outer cover. According to another embodiment, the second cover is dielectrically isolated from a current collector.

Abstract: An electrochemical cell constructed in accordance with the present invention includes a can for containing electrochemical materials including positive and negative electrodes and an electrolyte, the can having an open end and a closed end; a pressure relief mechanism formed in the closed end of the can for releasing internal pressure from within the can when the internal pressure becomes excessive; a first outer cover positioned on the closed end of the can to be in electrical contact therewith and to extend over the pressure relief mechanism; a second outer cover positioned across the open end of the can; and an insulator disposed between the can and the second outer cover for electrically insulating the can from the second outer cover. According to another embodiment, the second cover is dielectrically isolated from a current collector.