Abstract: An electrochemical cell comprising a cathode material contacted to a perforated current collector having a portion left uncovered and an anode material contacted to an anode current collector is described. A separator sheet segregating the anode from direct contact with the cathode is folded back upon itself along a crease with an upper portion at least partially sealed to a lower portion along an aligned peripheral edge to form an envelope. A first envelope portion houses the cathode having the uncovered portion of the cathode current collector spaced from the crease and a second envelope portion houses the anode. The first envelope portion is sealed to the second envelope portion through the uncovered perforations of the cathode current collector to lock the anode aligned with the cathode. The anode and cathode are then wound into a jellyroll electrode assembly housed in a cylindrical casing and activated with an electrolyte.

Abstract: A method of manufacturing an electrochemical cell is described. A separator sheet segregating the anode from direct contact with the cathode is folded back upon itself along a crease with an upper portion at least partially sealed to a lower portion along an aligned peripheral edge to form an envelope. A first envelope portion houses the cathode having an uncovered portion of the cathode current collector spaced from the crease and a second envelope portion houses the anode. The first envelope portion is sealed to the second envelope portion through uncovered perforations of the cathode current collector to lock the anode aligned with the cathode. The anode and cathode are then wound into a jellyroll electrode assembly housed in a cylindrical casing and activated with an electrolyte.

Abstract: An electrochemical cell is described. The cell comprises a cathode material contacted to a perforated current collector having a portion left uncovered and an anode material contacted to an anode current collector. The anode comprises first and second strips positioned on opposite sides of the cathode, which is also in the form of a strip, but one that is much longer than each of the anode strips. Proximal ends of the anode strips reside adjacent to where the cathode is secured to a terminal pin/sleeve assembly. Distal ends of the anode strips are adjacent to the opposed ends of the cathode strip. A separator sheet segregating the anode from direct contact with the cathode provides an upper portion at least partially sealed to a lower portion along an aligned peripheral edge and through the uncovered perforations of the cathode current collector to lock the cathode in position.

Abstract: An electrochemical cell comprising a cathode of a powder material pressed into intimate contact with a rod-shaped current collector and an anode at least partially wrapped around the cathode is described. The cathode current collector is preferably provided with a plurality of offset flats offset with respect to each other. This helps prevent the cathode active material from sliding off of the rod-shaped current collector. The anode has spaced apart edges at opposite ends of its width that form a gap with the anode wrapped around the cathode. This helps in sliding the anode/cathode electrode assembly into a cylindrical tube comprising the cell casing. A preferred chemistry is a lithium/CFx activated with a nonaqueous electrolyte.

Abstract: A primary lithium electrochemical cell housed in a casing having a curved side wall intermediate opposed generally planar face walls is described. The cell comprises an anode and a cathode that each has a plurality of face portions joined together by connecting portions. The opposite polarity face portions and connecting portions are aligned with each other and then the electrodes are wound to provide an electrode assembly that fits in the casing. Regardless whether the cell is balanced as either an anode-limited or cathode-limited configuration, however, it is desirable to have the active material of one electrode face portion directly facing the electrode material of the counter electrode face portion. This means that the dimensional extent of the facing electrodes should be as close to each other in areas as possible to match the desired anode- or cathode-limited balance. The same is true for the connecting portions. The cell is of a high energy density for an implantable biomedical device.

Abstract: an electrochemical cell comprising a cathode of a powder material pressed into intimate contact with a rod-shaped current collector and an anode at least partially wrapped around the cathode is described. The cathode current collector is preferably provided with a plurality of offset flats offset with respect to each other. This helps prevent the cathode active material from sliding off of the rod-shaped current collector. The anode has spaced apart edges at opposite ends of its width that form a gap with the anode wrapped around the cathode. This helps in sliding the anode/cathode electrode assembly into a cylindrical tube comprising the cell casing. A preferred chemistry is a lithium/CFx activated with a nonaqueous electrolyte.

Abstract: An electrochemical cell comprising a cathode material contacted to a perforated current collector having a portion left uncovered and an anode material contacted to an anode current collector is described. A separator sheet segregating the anode from direct contact with the cathode is folded back upon itself along a crease with an upper portion at least partially sealed to a lower portion along an aligned peripheral edge to form an envelope. A first envelope portion houses the cathode having the uncovered portion of the cathode current collector spaced from the crease and a second envelope portion houses the anode. The first envelope portion is sealed to the second envelope portion through the uncovered perforations of the cathode current collector to lock the anode aligned with the cathode. The anode and cathode are then wound into a jellyroll electrode assembly housed in a cylindrical casing and activated with an electrolyte.

Abstract: An insulator ring for preventing short circuit contact between the opposite polarity electrode in a case-terminal cell design is described. Typically, a lithium/silver vanadium oxide cell is built in a case-negative design with the casing serving at the negative terminal. The cathode is connected to an insulated terminal pin. In a conventional cell construction, the electrode assembly is enclosed in an insulator bag in addition to the electrode separator envelopes before being housed inside the casing. The insulator bag ensures the cathode electrode will not come into short circuit contact with the casing. In the present invention, the insulator bag is replaced with an insulator ring which only protects those portions of the electrode assembly vulnerable to short circuit contact.

Abstract: A unitary lid for the casing of an electrochemical energy storage device is described. The lid has a terminal lead ferrule and a fill port formed from a single blank in a machine process. The lid does not require any welding except for securing it to the open end of a casing container. The ferrule supports a terminal lead insulated therefrom by glass. A thermoplastic insulator material encases the ferrule and a portion of the terminal lead extending below the lid. In that manner, the insulator helps prevent contact between the anode and the cathode in the vicinity of the lid.

Abstract: The present invention is directed to an electrochemical cell having plate electrodes housed inside mating “clam shell” casing components. Also, the present casing design allows for indentation structures in the casing components by virtue of them being stamped metal parts. Such indentations are not possible with traditional cylindrical and prismatic casing designs. When mated together, the casing components are form-fitting with respect to the internal battery structure so as to reduce the overall size of the electrochemical package. This provides the cell with the greatest amount of energy per unit size.

Abstract: An alkali metal secondary electrochemical cell, and preferably a lithium ion cell, provided with a removable gas relief valve, is described. The gas release valve is positioned on the casing, in fluid flow communication between the inside thereof and the exterior. This gas release valve serves to eliminate cell gases that build up inside the casing during the cell's formation stage. Once the lithium-ion cell has completed formation, the gas release valve is removed and replaced with a hermetic closure. Removal of the gas release valve and sealing of the cell takes place in an environment in which no outside gas is capable of being introduced inside the casing. The cell can also be provided in a tank filled with inert gas and a filter which separates the cell gas from the inert gas. When cell formation is completed, the cell hermetically sealed.

Abstract: An insulator ring for preventing short circuit contact between the opposite polarity electrode in a case-terminal cell design is described. Typically, a lithium/silver vanadium oxide cell is built in a case-negative design with the casing serving at the negative terminal. The cathode is connected to an insulated terminal pin. In a conventional cell construction, the electrode assembly is enclosed in an insulator bag in addition to the electrode separator envelopes before being housed inside the casing. The insulator bag ensures the cathode electrode will not come into short circuit contact with the casing. In the present invention, the insulator bag is replaced with an insulator ring which only protects those portions of the electrode assembly vulnerable to short circuit contact.

Abstract: An alkali metal secondary electrochemical cell, and preferably a lithium ion cell, provided with a removable gas relief valve, is described. The gas release valve is positioned on the casing, in fluid flow communication between the inside thereof and the exterior. This gas release valve serves to eliminate cell gases that build up inside the casing during the cell's formation stage. Once the lithium-ion cell has completed formation, the gas release valve is removed and replaced with a hermetic closure. Removal of the gas release valve and sealing of the cell takes place in an environment in which no outside gas is capable of being introduced inside the casing. The cell can also be provided in a tank filled with inert gas and a filter which separates the cell gas from the inert gas. When cell formation is completed, the cell hermetically sealed.

Abstract: The present invention is directed to an electrochemical cell having plate electrodes housed inside mating “clam shell” casing components. Also, the present casing design allows for indentation structures in the casing components by virtue of them being stamped metal parts. Such indentations are not possible with traditional cylindrical and prismatic casing designs. When mated together, the casing components are form-fitting with respect to the internal battery structure so as to reduce the overall size of the electrochemical package. This provides the cell with the greatest amount of energy per unit size.