Abstract: 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.

Abstract: And end cap assembly and venting system therein for closing and sealing the open end of a cell housing. The end cap assembly comprises a sealing disk underlying an end cap, and a metal support disk between the end cap and the sealing disk. The metal support disk has a plurality of primary vent apertures and a plurality of secondary vent apertures through its surface. The primary vent apertures are spaced apart along a path located at a greater distance from the central longitudinal axis of the metal support disk than the secondary vent apertures. The insulating sealing disk may have a thinned portion therein forming an rupturable membrane circumventing the central hub of the sealing disk. The insulating sealing disk may have protrusions emanating from its top surface to deflect the membrane during rupture. The venting system releases internal gases rapidly from the cell in the event of an abusive or short circuit discharge.

Abstract: A wafer alkaline cell of a laminar structure is disclosed. The cell has a pair of opposing sides comprising at least the majority of the boundary surface of said cell and defining a short cell dimension therebetween. The cell comprises an anode assembly and a cathode assembly bonded together to form a laminate structure. The cell comprises a single plastic frame or two separate plastic frames housing the anode and cathode material. The anode current collector may be precoated with a sealing metal forming an alkaline resistant metal oxide film to improve bonding to the frame. The anode assembly has an anode material therein typically comprising zinc and the cathode assembly has a cathode material therein typically comprising manganese dioxide. The cell is durable and preferably rigid, has elongated leak block paths, and resists electrolyte leakage.

Abstract: An alkaline cell having a flat housing, preferably of cuboid shape. The housing may be laser welded closed with a metal cover inserted as a part of an end cap assembly. A portion of an insulating seal may be held compressed between a sleeve extending from the metal cover and an anode current collector nail within the end cap assembly. The housing may include a vent mechanism, preferably a grooved vent, which can activate, when gas pressure within the cell reaches a threshold level typically between about 250 and 800 psig (1724×103 and 5515×103 pascal gage). The cell can have a supplemental laser welded vent which may activate at higher pressure levels.

Abstract: A method of forming an anode comprising zinc for an alkaline cell. The method involves mixing zinc particles with binders including preferably polyvinylalcohol, surfactant and water to form a wet paste. The wet paste is molded into the near shape of the cell's anode cavity and then heated to evaporate water. A solid porous zinc mass is formed having microscopic void spaces between the zinc particles. The solid mass can be inserted into the cell's anode cavity and aqueous alkaline electrolyte, preferably comprising potassium hydroxide, then added. The solid mass absorbs the aqueous electrolyte and expands to fill the anode cavity to form the final fresh anode. Zinc fibers may be added to increase the structural integrity of the solid mass.

Abstract: A method of applying liquid adhesive to surfaces of components of an electrochemical cell employing a needle valve applicator. The liquid adhesive is applied by dispensing it through a tubular tip connected to a pneumatically actuated needle valve applicator. The method is effective in applying adhesive to narrow width or difficult to reach surfaces of cell components in a precise, consistent and reproducible manner. In a specific application the adhesive can be applied to the narrow recessed step surrounding the terminal portion of the cathode casing of a zinc/air button cell. In such application the cathode casing may typically be rotated at speeds of between about 50 and 1000 revolutions per minute as adhesive is applied thereto from the applicator. The adhesive provides a tight seal between the cathode casing and cathode assembly, thereby preventing leakage of electrolyte from the cell.

Abstract: An alkaline cell having a flat casing, preferably of cuboid shape. The cell can have an anode comprising zinc and a cathode comprising nickel oxyhydroxide. The casing can have a relatively small overall thickness, typically between about 5 and 10 mm, but may be larger. Cell contents can be supplied through an open end in the casing and an end cap assembly inserted therein to seal the cell. The end cap assembly includes a vent mechanism, preferably a grooved vent, which can activate, when gas pressure within the cell reaches a threshold level typically between about 250 and 800 psig (1724×103 and 5515×103 pascal gage). The cell can have a supplemental vent mechanism such as a laser welded region on the surface of the casing which may activate at higher pressure levels.

Abstract: A wafer alkaline cell of a laminar structure is disclosed. The cell has a pair of opposing sides comprising at least the majority of the boundary surface of said cell. The opposing sides define a short cell dimension therebetween. The cell comprises an anode assembly and a cathode assembly bonded together to form a laminate structure. The cell comprises a single frame or two separate frames housing the anode and cathode material. The anode assembly has an anode material therein typically comprising zinc and the cathode assembly has a cathode material therein typically comprising manganese dioxide. The cell is durable and preferably rigid, has elongated leak block paths, and resists electrolyte leakage.

Abstract: An alkaline cell having a flat housing, preferably of cuboid shape. The cell can have an anode comprising zinc and a cathode comprising MnO2. The housing can have a relatively small overall thickness, typically between about 5 and 10 mm. Cell contents can be supplied through an open end in the housing and an end cap assembly inserted therein to seal the cell. There can be a gap between separator and cathode for insertion of additional electrolyte. The end cap assembly includes a vent mechanism, preferably a grooved vent, which can activate, when gas pressure within the cell reaches a threshold level typically between about 250 and 800 psig (1724×103 and 5515×103 pascal gage). The cell can have a supplemental vent mechanism such as a laser welded region on the surface of the housing which may activate at higher pressure levels.

Abstract: An alkaline cell having a flat housing, preferably of cuboid shape. The cell can have an anode comprising zinc and a cathode comprising MnO2. The housing can have a relatively small overall thickness, typically between about 5 and 10 mm. Cell contents can be supplied through an open end in the housing and an end cap assembly inserted therein to seal the cell. There can be a gap between separator and cathode for insertion of additional electrolyte. The end cap assembly includes a vent mechanism, preferably a grooved vent, which can activate, when gas pressure within the cell reaches a threshold level typically between about 250 and 800 psig (1724×103 and 5515×103 pascal gage). The cell can have a supplemental vent mechanism such as a laser welded region on the surface of the housing which may activate at higher pressure levels.

Abstract: A primary alkaline battery includes a cathode including a nickel oxyhydroxide and an anode including zinc or zinc alloy particles. Performance of the nickel oxyhydroxide alkaline cell is improved by adding zinc fines to the anode.

Abstract: A zinc/air button cell, wherein the cell has a single casing, namely, the anode can. A substantially flat metal support disk is employed, to close the open end of the anode can, thus eliminating the need for the conventional cathode can. The metal support disk is locked in place within the open end of the anode can with insulating sealing material therebetween. The sealing material abuts a greater portion of the inside surface of the anode can than the outside surface of said can. A layer of cathode material comprising a manganese oxide, underlies the metal support disk. The cathode is locked in place against the metal support disk. The open end of the anode can is crimped axially and radially over the metal support disk with insulating sealing material therebetween. A tight seal results and the cell capacity is increased, since the cathode can has been eliminated.

Abstract: A method of forming an anode comprising zinc for a zinc/air cell. The method involves mixing zinc particles with binders including preferably polyvinylalcohol, surfactant and water to form a wet paste. The wet paste is compacted and molded into the near shape of the cell's anode cavity and then heated to evaporate water. A solid porous zinc mass is formed wherein the zinc particles are held bound within a network with microscopic void spaces between the zinc particles. The solid mass can be inserted into the cell's anode cavity and aqueous alkaline electrolyte, preferably comprising potassium hydroxide, then added. The solid mass absorbs the aqueous electrolyte and expands to fill the anode cavity to form the final fresh anode.

Abstract: An alkaline cell having a flat housing, preferably of cuboid shape. The cell can have an anode comprising zinc and a cathode comprising MnO2. The housing can have a relatively small overall thickness, typically between about 5 and 10 mm. Cell contents can be supplied through an open end in the housing and an end cap assembly inserted therein to seal the cell. The end cap assembly includes a vent mechanism which can activate, when gas pressure within the cell reaches a threshold level typically between about 100 and 300 psig (6.89×105 and 20.69×105 pascal gage). The cell can have primary and supplemental vent mechanisms such as welded or thinned regions on the surface of the housing which may activate at different pressure levels. The cathode can be formed of a plurality of stacked slabs having aligned hollow centers with an elongated opening for anode material to be inserted therein.

Abstract: A method of forming an anode comprising zinc for an alkaline cell. The method involves mixing zinc particles with binders including preferably polyvinylalcohol, surfactant and water to form a wet paste. The wet paste is molded into the near shape of the cell's anode cavity and then heated to evaporate water. A solid porous zinc mass is formed having microscopic void spaces between the zinc particles. The solid mass can be inserted into the cell's anode cavity and aqueous alkaline electrolyte, preferably comprising potassium hydroxide, then added. The solid mass absorbs the aqueous electrolyte and expands to fill the anode cavity to form the final fresh anode.

Abstract: An alkaline cell having a flat housing, preferably of cuboid shape. The cell can have an anode comprising zinc and a cathode comprising MnO2. The housing can have a relatively small overall thickness, typically between about 5 and 10 mm. Cell contents can be supplied through an open end in the housing and an end cap assembly inserted therein to seal the cell. The end cap assembly includes a vent mechanism which can activate, when gas pressure within the cell reaches a threshold level typically between about 100 and 300 psig (6.89×105 and 20.69×105 pascal gage). The cell can have primary and supplemental vent mechanisms such as welded or thinned regions on the surface of the housing which may activate at different pressure levels. The cathode can be formed of a plurality of stacked slabs having aligned hollow centers with an elongated opening for anode material to be inserted therein.