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 primary lithium cell having an anode comprising lithium and a cathode comprising electrochemically active material selected from copper vanadates having the formula CuV2O6 or Cu2V2O7 or mixtures thereof. The cathode can include a manganese dioxide in admixture with said copper vanadates. The cell exhibits higher capacity and energy output than conventional lithium cells having an anode comprising lithium and cathode comprising manganese dioxide.

Abstract: 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).

Abstract: 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.

Abstract: An end cap seal assembly for an electrochemical cell such as an alkaline cell is disclosed. The end cap assembly comprises a convoluted end cap which may also function as a cell terminal and an underlying insulating sealing disk. The insulating sealing disk comprises a central boss and radially extending arm terminating in a downwardly sloped elbow and upwardly sloped peripheral edge. The end cap disk has at least one vent aperture therethrough which faces the ambient environment. The insulating disk has an annular groove in its top or bottom surface, which preferably circumvents the central boss. The base of the groove defines an a rupturable membrane portion of the insulating sealing disk. The rupturable membrane is designed to rupture, preferably when the cell internal gas pressure reaches a level between about 150 and 900 psig (1034×103 and 6206×103 pascal gage) advantageously, between about 150 and 700 psig (1034×103 and 4827×103 pascal gage).

Abstract: An alkaline battery includes a cathode including a nickel oxyhydroxide and an anode including zinc or zinc alloy particles.

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 an insulating sealing member having a circumferential skirt which surrounds wide portions of the anode current collector. This provides a barrier between said wide portions of the current collector and the cell housing. The end cap assembly includes a vent mechanism which can activate, when gas pressure within the cell reaches a level typically between about 100 and 300 psig (6.89×105 and 20.69×105 pascal gage). The cathode can be formed of a plurality of stacked slabs having aligned hollow centers forming a central core with anode material placed therein. A separator is between anode and cathode.

Abstract: Particulate MnO2, having simultaneously a micropore surface area greater than 8.0 m2/g, desirably between about 8.0 and 13 m2/g and BET surface area of between about 20 and 31 m2/g within the context of an MnO2 having a total intraparticle porosity of between about 0.035 cm3/g and 0.06 cm3/g produces enhanced performance when employed as cathode active material in an electrochemical cell, particularly an alkaline cell. The average pore radius of the meso and macro pores within the MnO2 (meso-macro pore radius) is desirably greater than 32 Angstrom.

Abstract: A flat elongated alkaline battery comprising an outer metal housing and a single alkaline cell encased within a hydrogen permeable plastic container which is housed within the interior of the metal housing. The outer housing has at least a major surface which is a flat polygon. Preferably the outer metal housing is a cuboid.

Abstract: An alkaline cell having an anode comprising zinc, a cathode comprising manganese dioxide and an electrolyte comprising polyvinylbenzyltrimethylammoniumhydroxide. The anode can comprise particulate zinc dispersed within an aqueous gel comprising crosslinked polyvinylbenzyltrimethylammoniumhydroxide polymer. Optionally, aqueous KOH can be added to the gel. The anode and cathode are desirably in the shape of a slab each having a pair of opposing parallel flat faces defining two opposing ends. The zinc particles dispersed in crosslinked polyvinylbenzytrimethylammoniumhydroxide polymer can be concentrated at one end of the anode slab with the opposing end being clear of zinc. The clear end of the anode preferably also comprising polyvinylbenzlytrimethylammoniumhydroxide functions as a separator between anode and cathode. The cathode slab comprises a mixture of particulate manganese dioxide, graphite, and linear polyvinylbenzyltrimethylammoniumhydroxide polymer.

Abstract: An electrochemical cell generating hydrogen gas upon discharge, wherein the cell has an outer casing, a vent aperture passing through a wall of the casing, and a rupturable membrane covering the vent aperture. The outer casing preferably has a flat wall running along the cell's length and a vent aperture passing through the flat wall. The cell may typically be an alkaline cell in the shape of a cuboid. The rupturable membrane may be secured by a ring facing the inside surface of the flat wall of the casing in a position adjacent the vent aperture. The rupturable membrane is preferably of polysulfone. The membrane allows hydrogen gas to permeate therethrough to the environment and is rupturable if hydrogen gas within the cell interior builds up rapidly to a threshold pressure level. Optionally, a pointed puncture member extends into the vent aperture to assist membrane rupture.

Abstract: An end cap seal assembly for an electrochemical cell such as an alkaline cell is disclosed. The end cap assembly comprises a convoluted metal support disk and underlying insulating sealing disk. The convoluted support disk has a downwardly extending wall with at least one aperture therethrough which preferably faces the ambient environment. The insulating disk has a slanted downwardly extending wall forming a rupturable membrane which underlies and abuts the inside surface of the downwardly extending wall of the support disk. The rupturable membrane is slanted downwardly at an acute angle with the cell's longitudinal axis. The rupturable membrane underlies and abuts the aperture in the downwardly extending wall of the end cap. When gas pressure within the cell exceeds a predetermined level the rupturable membrane pushes through said aperture and ruptures allowing gas to escape therefrom to the environment. A separate terminal plate can be stacked onto the metal support disk and welded thereto.

Abstract: A primary lithium cell having an anode comprising lithium and a cathode comprising electrochemically active material selected from silver copper oxides having the formula AgCuO2 or Ag2Cu2O3 or mixtures thereof. The cathode can include a manganese dioxide in admixture with said silver copper oxides. The cell exhibits higher capacity and energy output than conventional lithium cells having an anode comprising lithium and cathode comprising manganese dioxide.

Abstract: Particulate MnO2, having simultaneously a micropore surface area greater than 8.0 m2/g, desirably between about 8.0 and 13 m2/g and BET surface area of between about 20 and 31 m2/g within the context of an MnO2 having a total intraparticle porosity of between about 0.035 cm3/g and 0.06 cm3/g produces enhanced performance when employed as cathode active material in an electrochemical cell, particularly an alkaline cell. The average pore radius of the meso and macro pores within the MnO2 (meso-macro pore radius) is desirably greater than 32 Angstrom.

Abstract: An alkaline cell having an anode comprising zinc, an aqueous alkaline electrolyte, a cathode mixture comprising cathode active material comprising copper oxide or copper hydroxide. Graphitic carbon, preferably expanded graphite or graphitic carbon nanofibers are added to the cathode mixture thereby resulting in a sharp drop in cathode resistivity. The cathode active material preferably comprises between about 80 and 92 percent by weight of the cathode. The sharp drop in cathode resistivity resulting from the addition of expanded graphite or graphitic carbon nanofibers makes the cell suitable for use as a primary alkaline cell having good capacity. The graphitic carbon, preferably graphitic nanofibers comprise preferably between about 4 and 10 percent by weight of the cathode. The carbon nanofibers have an average diameter desirably less than 500 nanometers, preferably between about 50 and 300 nanometers.

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 an insulating sealing member having a circumferential skirt which surrounds wide portions of the anode current collector. This provides a barrier between said wide portions of the current collector and the cell housing. The end cap assembly includes a vent mechanism which can activate, when gas pressure within the cell reaches a level typically between about 100 and 300 psig (6.89×105 and 20.69×105 pascal gage). The cathode can be formed of a plurality of stacked slabs having aligned hollow centers forming a central core with anode material placed therein. A separator is between anode and cathode.

Abstract: 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.