Patents by Inventor Keith Buckle
Keith Buckle has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).
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Patent number: 7582125Abstract: A method of forming a nickel layer on a metal substrate forming the terminal contact area of the cathode casing for a zinc-air cell. A cathode casing in desired shape and size for a zinc-air cell is formed of a substrate metal such as cold rolled steel or stainless steel. A nickel layer is plated onto the cathode casing substrate metal over the terminal contact area and is subsequently heat treated resulting in reduction in the surface hardness. The method of heat treatment involves heating the substrate metal with nickel plated thereon in an inert atmosphere at temperatures preferably between about 860° F. and 135° F. The method reduces the nickel surface hardness to a level below 8 GPa. This improves the electrical contact with the hearing aid or other device being powered.Type: GrantFiled: November 26, 2004Date of Patent: September 1, 2009Assignee: The Gillette CompanyInventors: Keith Buckle, Leo White, David L. Pappas
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Publication number: 20060115724Abstract: A zinc-air cell with an anode cup comprising anode active material and a cathode cup comprising catalytic or cathode active material wherein the cathode cup comprises an exposed nickel layer which has been softened to improve electrical contact with the device being powered such as a hearing aid. A cathode cup in desired shape and size is formed of a substrate metal such as cold rolled steel or stainless steel. A nickel layer is plated onto the cathode cup substrate metal and is subsequently heat treated resulting in reduction in the surface hardness of the nickel layer. This improves the reliability of the electrical contact between the cathode cup and the corresponding terminal in the hearing aid or other device being powered.Type: ApplicationFiled: November 26, 2004Publication date: June 1, 2006Inventors: Keith Buckle, Leo White, David Pappas
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Patent number: 7001689Abstract: A zinc/air cell having thin walled cup shaped anode casing and cathode casing. The cell may be a button cell having an anode comprising zinc and a cathode, which may be catalytic, comprising manganese dioxide. The anode and cathode casings have small wall thicknesses, preferably between 2 and 5 mil (0.0508 and 0.127 mm), desirably between about 2 and 3 mil (0.0508 and 0.0762 mm). There is an insulating seal ring covering at least a portion of the anode casing side walls. During cell assembly the cathode casing side wall is pushed over at least a portion of the anode casing side wall with insulating sealing disk therebetween. A tight interference fit is achieved with the outside diameter of the anode casing plus insulating seal thereon being preferably between about 2 and 4.5 mil (0.0508 and 0.114 mm) greater than the inside diameter of the cathode casing. This reduces the tendency of the casing side walls to spring back after crimping.Type: GrantFiled: April 2, 2003Date of Patent: February 21, 2006Assignee: The Gillette CompanyInventor: Keith Buckle
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Patent number: 7001439Abstract: An assembly process for manufacture of zinc/air cells, typically zinc/air button cells. The cells have a cup shaped anode casing and cup shaped cathode casing, each having an open and closed end. The process comprises an assembly step wherein the two casings are pushed together, followed by a crimping step wherein the cell is punched through a die thereby crimping the cathode casing edge over the anode casing side wall with insulator seal therebetween. In each step, particularly in the crimping step, an anode punch having an annular protruding surface impacts the corner edge of the closed end of the anode casing while another punch is applied with an opposing force to the cathode casing. The process has particular utility for anode and cathode casings of small wall thickness, preferably between 2 and 5 mil (0.0508 and 0.127 mm).Type: GrantFiled: April 2, 2003Date of Patent: February 21, 2006Assignee: The Gillette CompanyInventor: Keith Buckle
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Patent number: 6830847Abstract: A zinc/air button cell comprising a cathode casing and an anode casing wherein the anode casing is inserted into the cathode casing. The anode casing is formed of multiclad metal layers, for example nickel/stainless steel/copper. A protective metal is plated onto the exposed peripheral edge of the anode casing. The protective metal is desirably selected from copper, tin, indium, silver, brass, bronze or gold. The application of the protective metal covers the multiclad metals exposed along the peripheral edge surface. The protective metal is also desirably plated onto the portion of the outside surface of the anode casing abutting the insulating material placed between the anode and cathode casing. Application of the protective metal to the anode casing peripheral edge eliminates the potential gradients caused by exposure of the different metals comprising the multiclad material.Type: GrantFiled: April 10, 2001Date of Patent: December 14, 2004Assignee: The Gillette CompanyInventors: Karthik Ramaswami, Daniel Gibbons, Keith Buckle
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Publication number: 20040197644Abstract: A zinc/air cell having thin walled cup shaped anode casing and cathode casing. The cell may be a button cell having an anode comprising zinc and a cathode, which may be catalytic, comprising manganese dioxide. The anode and cathode casings have small wall thicknesses, preferably between 2 and 5 mil (0.0508 and 0.127 mm), desirably between about 2 and 3 mil (0.0508 and 0.0762 mm). There is an insulating seal ring covering at least a portion of the anode casing side walls. During cell assembly the cathode casing side wall is pushed over at least a portion of the anode casing side wall with insulating sealing disk therebetween. A tight interference fit is achieved with the outside diameter of the anode casing plus insulating seal thereon being preferably between about 2 and 4.5 mil (0.0508 and 0.114 mm) greater than the inside diameter of the cathode casing. This reduces the tendency of the casing side walls to spring back after crimping.Type: ApplicationFiled: April 2, 2003Publication date: October 7, 2004Inventor: Keith Buckle
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Publication number: 20040197645Abstract: A zinc/air cell having thin walled cup shaped anode casing and cathode casing. The cell may be a button cell having an anode comprising zinc and a cathode disk, which may be catalytic, comprising manganese dioxide. The anode and cathode casings each have small wall thicknesses, preferably between 2 and 5 mil (0.0508 and 0.127 mm), desirably between about 2 and 3 mil (0.0508 and 0.0762 mm). The cathode disk is inserted and then punched into the cathode casing so that the disk is pressed towards the closed end of the cathode casing. This causes the cathode disk to expand radially between the cathode disk and inside surface of the cathode casing, reducing the chance of electrolyte leakage around the edge of the cathode disk. The diameter of the cathode disk is preferably between about 0.5 and 2.5 mil (0.0127 and 0.0635 mm) greater than the inside diameter of the cathode casing after the disk is punched into the cathode casing.Type: ApplicationFiled: April 2, 2003Publication date: October 7, 2004Inventor: Keith Buckle
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Publication number: 20040197643Abstract: An assembly process for manufacture of zinc/air cells, typically zinc/air button cells. The cells have a cup shaped anode casing and cup shaped cathode casing, each having an open and closed end. The process comprises an assembly step wherein the two casings are pushed together, followed by a crimping step wherein the cell is punched through a die thereby crimping the cathode casing edge over the anode casing side wall with insulator seal therebetween. In each step, particularly in the crimping step, an anode punch having an annular protruding surface impacts the corner edge of the closed end of the anode casing while another punch is applied with an opposing force to the cathode casing. The process has particular utility for anode and cathode casings of small wall thickness, preferably between 2 and 5 mil (0.0508 and 0.127 mm).Type: ApplicationFiled: April 2, 2003Publication date: October 7, 2004Inventor: Keith Buckle
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Patent number: 6526799Abstract: A casing for cylindrical electrochemical cells, for example, alkaline cells or lithium cells. The casing is characterized by having a non-uniform wall thickness. The casing comprises a cylindrical body surface, an open end and an integrally formed closed bottom. A portion of the casing body forms the peripheral edge of the casing at the open end thereof. The casing body surface has a wall thickness which is less than the wall thickness of the casing bottom. The casing has a peripheral edge which has a wall thickness which is greater than the wall thickness of the body surface. The peripheral edge wall thickness is desirably about the same or greater than the wall thickness of the casing bottom. The casing is formed by subjecting a sheet of metal to a series of discrete punching steps. A partially formed cup is punched through a die cavity in each step thereby progressively drawing the cup to a progressively reduced diameter and increased length.Type: GrantFiled: February 28, 2002Date of Patent: March 4, 2003Assignee: The Gillette CompanyInventors: Charles R. Ferraro, Sean A. Sargeant, Jay Lucas, Keith Buckle
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Publication number: 20020192545Abstract: A zinc/air button cell comprising a cathode casing and an anode casing wherein the anode casing is inserted into the cathode casing. The anode casing is formed of multiclad metal layers, for example nickel/stainless steel/copper. A protective metal is plated onto the exposed peripheral edge of the anode casing. The protective metal is desirably selected from copper, tin, indium, silver, brass, bronze or gold. The application of the protective metal covers the multiclad metals exposed along the peripheral edge surface. The protective metal is also desirably plated onto the portion of the outside surface of the anode casing abutting the insulating material placed between the anode and cathode casing. Application of the protective metal to the anode casing peripheral edge eliminates the potential gradients caused by exposure of the different metals comprising the multiclad material.Type: ApplicationFiled: April 10, 2001Publication date: December 19, 2002Inventors: Karthik Ramaswami, Daniel Gibbons, Keith Buckle
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Publication number: 20020081490Abstract: A casing for cylindrical electrochemical cells, for example, alkaline cells or lithium cells. The casing is characterized by having a non-uniform wall thickness. The casing comprises a cylindrical body surface, an open end and an integrally formed closed bottom. A portion of the casing body forms the peripheral edge of the casing at the open end thereof. The casing body surface has a wall thickness which is less than the wall thickness of the casing bottom. The casing has a peripheral edge which has a wall thickness which is greater than the wall thickness of the body surface. The peripheral edge wall thickness is desirably about the same or greater than the wall thickness of the casing bottom. The casing is formed by subjecting a sheet of metal to a series of discrete punching steps. A partially formed cup is punched through a die cavity in each step thereby progressively drawing the cup to a progressively reduced diameter and increased length.Type: ApplicationFiled: February 28, 2002Publication date: June 27, 2002Inventors: Charles R. Ferraro, Sean A. Sargeant, Jay Lucas, Keith Buckle
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Patent number: D426188Type: GrantFiled: August 20, 1999Date of Patent: June 6, 2000Assignee: The Gillette CompanyInventor: Keith Buckle
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Patent number: D426189Type: GrantFiled: August 20, 1999Date of Patent: June 6, 2000Assignee: The Gillette CompanyInventor: Keith Buckle
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Patent number: D426514Type: GrantFiled: August 20, 1999Date of Patent: June 13, 2000Assignee: The Gillette CompanyInventor: Keith Buckle
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Patent number: D426515Type: GrantFiled: August 20, 1999Date of Patent: June 13, 2000Assignee: The Gillette CompanyInventor: Keith Buckle
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Patent number: D426516Type: GrantFiled: August 20, 1999Date of Patent: June 13, 2000Assignee: The Gillette CompanyInventor: Keith Buckle
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Patent number: D426517Type: GrantFiled: August 20, 1999Date of Patent: June 13, 2000Assignee: The Gillette CompanyInventor: Keith Buckle
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Patent number: D426806Type: GrantFiled: August 20, 1999Date of Patent: June 20, 2000Assignee: The Gillette CompanyInventor: Keith Buckle
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Patent number: D426807Type: GrantFiled: August 20, 1999Date of Patent: June 20, 2000Assignee: The Gillette CompanyInventor: Keith Buckle
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Patent number: D427144Type: GrantFiled: August 20, 1999Date of Patent: June 27, 2000Assignee: The Gillette CompanyInventor: Keith Buckle