Abstract: The present invention is a process for producing a silver layer, in situ, on an internal wall of a cathode container of an alkaline cell and the alkaline cell produced by the process. In the process a silver compound is dissolved in the cathode, which is in contact with the metal container of the cell, and silver ions diffuse through the cathode and displace metal on the inside surface of the container to coat the container surface with silver.

Abstract: A forming die includes a base and at least two die segments. At least a first one of the die segments is moveably mounted to the base for shifting between closed and opened positions. The die segments together define a cavity having an opening when the first die segment is in the closed position. A punch is moveably mounted to the base for shifting between a retracted position and an extended position wherein the punch crimps a part positioned within the cavity. A powered actuator is connected to at least the first one of the die segments, and shifts the first die segment between the closed and opened positions such that a part positioned within the cavity can be removed after crimping by shifting of the first die segment to the open position. The forming die is particularly well-suited for crimping electrochemical cells.

Abstract: An electrochemical cell having a container with a closed bottom end, an open top end, and side walls extending between the bottom and top ends. The container has a plurality of beads extending radially inward formed near the open top end. Electrochemically active material is disposed in the container, and a seal assembly is disposed in the open end and supported by the plurality of beads.

Abstract: An electrochemical cell is provided having a non-cylindrical container including one or more side walls each having a curved surface that curves radially inward. The electrochemical cell further includes first and second electrodes and a separator disposed therebetween. A cover and seal assembly is assembled to the top open end of the container. The radially inwardly curved surface of the side walls opposes forces caused by internal pressure within the cell so as to reduce and/or prevent bulging of the side walls.

Abstract: The invention relates to a housing which receives dry cells in an in-line or end to end orientation. The invention includes features which prevent the incorrect orientation by preventing dry cell terminals making contact with the necessary components. In this way, it prevents premature dissipation of dry cells or their impairment. The mechanism by which these features do this is to recess one terminal namely that terminal which would be contacted by the positive terminal of a dry cell. In this way, the negative terminal of a dry cell can never make electrical connection. Another feature of the invention is the provision of an aperture having a profile of a silhouette of a dry cell, which has advantages in low light situations, saves material, and allows for relatively easy extraction of dry cells from the cartridge.

Abstract: A portable lighting device according to the present invention includes a battery housing, a light source supported at a first end of the battery housing, and a shroud extending outward from the first end of the battery housing circumferentially around the light source. The shroud is preferably formed of a translucent material having a partially reflective inner surface for reflecting a portion of incident light emitted from the light source in a forward direction while allowing a portion of the incident light to be transmitted through the shroud and dispersed in peripheral directions. The shroud further preferably includes a diffusing outer surface for diffusing the incident light that is transmitted through the shroud. A shroud is preferably integrally formed with a collar portion as used for threading the integrated head structure onto the battery housing. Additionally, a protective lens cover that may include a collimating lens is also integrally formed in this head structure.

Abstract: The invention pertains to housings and enclosures for assemblies of electrochemical cells such as used in consumer electronic devices. A system of structural elements having constant cross-section along at least one axis is provided to construct protective housings for electrochemical cell assemblies. Where cell assemblies include sensitive circuit elements such as circuit boards the fabricated housings include cover portions to reduce the chance of impact or contact damage to the circuit elements. By designing structural elements having open and constant cross-sections, a family of housing components may be fabricated from a single structural element by altering a length. Different configuration housings may also be constructed by rearranging the housing components or introducing additional interconnecting components. By incorporating a unified interconnecting element into each component, interchangeability is increased.

Abstract: Paper for use as a separator in an electrochemical cell completely absorbs a 50 &mgr;l drop of water placed thereon in a time of not less than four minutes and not greater than fifteen minutes at 20° C. and provides an improve cell having less leakage and corrosive, especially in a mercury-free cell.

Abstract: An electrode is disclosed that includes at least one ribbon of electrochemically active material. By forming a negative electrode of zinc ribbons, the high-rate discharge capacity of the negative electrode is significantly increased. Consequently, the high-rate service of an electrochemical cell having the inventive electrode structure is improved.

Abstract: An electrolyte solvent system for use in electrochemical cells in which the electrolyte solvent system consists essentially of a dioxolane-based solvent and a dimethoxyethane-based solvent in a weight ratio of about 1:3. Also disclosed are electrolyte solutions and electrochemical cells comprising such a solvent system.

Abstract: An improved current collector for electrochemical cells is formed of a conductive porous foam. The foam is preferably a nickel foam as is often used as an electrochemical cell substrate. The high porosity foam's compressibility and resiliency provide an adaptive contact surface which accommodates variations in the shape and position of electrodes and other circuit elements. By using this material as an improved current collector, electrochemical cells are more easily produced with reduced internal resistance. Improved methods of assembly are a result of the nature of the high porosity foam material and its compliance. The foam collector may be used as a pressure connection or welded to the spiral edge of jelly-roll electrode assemblies. To increase effective contact area and also improve resistance to vibration forces, portions of the collector are compressed in a radial space between a jelly-roll assembly and the surrounding container.

Abstract: An electrochemical cell containing a snap-through sealing gasket that has a compressive preloading on a selected area of the snap-through gasket to prevent premature venting of the cell.

Abstract: A display card retains a flashlight thereon, wherein the flashlight has a body comprising two body halves, each body half defining a portion of an interior cavity and are matingly abutted one to the other. The mated halves further define at least two slots therein. The display card comprises a semi-rigid card defining a cutout that receives at least a portion of the flashlight. At least two tabs extend into the cutout, and each of the tabs is received in a different one of the slots. The tabs extend into the interior cavity of the flashlight in a manner to suspendingly retain the flashlight in the cutout for display.

Abstract: An alkaline electrochemical cell having a barium compound additive in the anode according to one embodiment, and in both the anode and the cathode according to another embodiment. The anode of the present invention comprises an active anode material such as zinc, and an anode additive comprising a barium compound, such as barium sulfate in the amount of up to 8% by weight of active anode materials. According to another embodiment, the cathode of the electrochemical cell comprises an active cathode material, such as manganese dioxide, and also has an additive comprising a barium compound, such as barium sulfate. The anode and cathode of the present invention are particularly adapted for use in an electrochemical cell having an alkaline electrolyte.

Abstract: A battery including a polar solvent transportive, ionically conductive separator formed directly on an electrode is prepared by applying a coating composition containing a polymer or gel dispersed in a polar solvent directly to the electrode surface and solidifying materials in the coating composition to form a separator membrane.

Abstract: A battery tester for use in combination with a portable lighting device such as a flashlight or lantern having a housing for retaining at least one battery including first and second terminals, each in electrical contact with an opposite pole of the battery, a conductor located on the exterior of the housing and having one end in electrical contact with the first terminal and an opposite end operably connectable to the second terminal. An indicator material overlies and is in responsive contact with the conductor to respond to and indicate a state that is present in the conductor. The indicator material is preferably a thermochromic ink responsive to heat changes in the conductor caused by a current flowing therethrough. The conductor and indicator material are preferably mounted on a flexible substrate imprinted with decorative ink and indicia and protected by a transparent protective layer.

Abstract: The present invention relates to a circuit for a portable lighting product such as flashlight, lantern, desk lamp, area light, combination area light and flashlight, front and rear bicycle light, emergency light, night light, rechargeable versions of any of those products previously mentioned, in which several power sources are provided. The invention includes the feature that each power source is electrically isolate from each other by the switch in mechanism or mechanisms, when the portable lighting product is switched to the off condition. The power sources can include single dry cells, or sets of series connected dry cells of any number.